Heavy Duty Connectors

Heavy Duty Connectors - Assemblies

Part Number	Description / PDF	Quantity
10200030002PG HARTING	CONN ASSY TOP ENTRY 3+GND SZ3A	0
0936030019 Woodhead - Molex	COMPLETE SET M/F 4P/PG11	0
10360050002 HARTING	HAN-KIT-EXQ5 QUICKLOCK - HAN EX	0
09120084722 HARTING	HAN-POWER T MOD TWIN RED 120V CC	0
0936030075 Woodhead - Molex	COMPLETE SET M/F 16P/M25	0
10200040004 HARTING	CONN ASSY TOP ENTRY 4+GND A3 M20	1
0936060467 Woodhead - Molex	7832.4700.0 + 2000.3027.0	0
1607346 Phoenix Contact	CONN FRAME AND INSERT 11+GND	0
0936030107 Woodhead - Molex	COMPLETE SET M/F 36P/M50	0
1802360000 Weidmuller	CONN ASSY TOP ENTRY 48+GND SZ12	0
0936030089 Woodhead - Molex	COMPLETE SET M/F 24P/M25	0
0936030109 Woodhead - Molex	COMPLETE SET M/F 36P/M50	0
0936060486 Woodhead - Molex	7832.4705.0 + 2000.3024.0	0
1854381 Phoenix Contact	VC-EMV4/5M-SET	0
1416359 Phoenix Contact	STA CONNECTOR SET B24 METAL HOUS	3
73101000032 HARTING	HAN-KIT - 24DD METAL,24+GND, SIN	0
1602290 Phoenix Contact	CONN ASSY SIDE ENTRY 6POS M20	0
0936060474 Woodhead - Molex	7832.4705.0 + 2000.3002.0	0
0936030040 Woodhead - Molex	COMPLETE SET WITH CABLE GLAND	0
1607239 Phoenix Contact	CONN FRAME AND INSERT 15+GND	0

Heavy Duty Connectors - Assemblies

1. Overview

Heavy Duty Connectors - Assemblies are robust electromechanical components designed to establish reliable connections in demanding environments. They enable power transmission and signal routing in industrial, transportation, energy, and infrastructure applications. These connectors are engineered to withstand extreme temperatures, vibration, moisture, and mechanical stress, ensuring operational continuity in critical systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Industrial Circular Connectors	High mating cycles, IP65+ sealing, threaded coupling	Factory automation systems, robotics
Heavy-Duty Power Connectors	High current capacity (up to 1000A), arc-resistant materials	Electric vehicle charging stations, industrial machinery
Hermetic Connectors	Gas-tight seals, vacuum compatibility	Aerospace systems, semiconductor manufacturing
Modular Hybrid Connectors	Combined power/signal/optical transmission	Railway traction systems, renewable energy

3. Structure and Components

Typical assemblies comprise:

Die-cast metal/polymer housing with anti-corrosion coating
Multi-pin contact modules with gold-plated copper alloys
Integral sealing gaskets (EPDM or silicone rubber)
Retention mechanisms (bayonet, threaded, or push-pull locks)
EMI/RFI shielding layers for signal integrity

4. Key Technical Specifications

Parameter	Importance
Current Rating (10-1000A)	Determines power transmission capacity
Voltage Range (50-1500V)	Defines electrical insulation requirements
Contact Resistance (<5m )	Impacts thermal stability and energy efficiency
Operating Temperature (-55 C to +150 C)	Ensures material stability in extreme conditions
Mechanical Life (500-10,000 cycles)	Dictates maintenance intervals and longevity

5. Application Areas

Primary industries include:

Energy: Wind turbines, solar inverters, grid storage systems
Transportation: Electric buses, locomotives, mining equipment
Manufacturing: CNC machines, welding robots, conveyor systems
Infrastructure: Smart grid components, tunnel ventilation systems

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
TE Connectivity	DEUTSCH HD Series	IP69K rating, 400A capacity, aerospace qualified
Amphenol Industrial	Centaur Plus	Hybrid power/signal, 600V/200A, quick-mate design
Phoenix Contact	Heavycon System	Modular configuration, vibration-resistant, tool-less assembly

7. Selection Guidelines

Key considerations:

Environmental factors (temperature, chemicals, ingress protection)
Electrical parameters (current, voltage, signal type)
Mechanical requirements (vibration, mating force, durability)
Compliance with standards (IEC 61435, UL 486A/B)
Maintenance accessibility and total cost of ownership

8. Industry Trends

Current developments focus on:

Smart connectors with integrated sensors for condition monitoring
Lightweight composite materials reducing weight by 30%
Eco-friendly plating processes (RoHS/WEEE compliance)
Higher power density designs (30% smaller footprint)
Expansion of 1500V DC connector systems for renewable energy