Heavy Duty Connectors

Heavy Duty Connectors - Assemblies

Part Number	Description / PDF	Quantity
0936060459 Woodhead - Molex	7832.4700.0 + 2000.3008.0	0
0936030046 Woodhead - Molex	COMPLETE SET WITH CABLE GLAND	0
1607407 Phoenix Contact	CONN FRAME AND INSERT 23+GND	2
1409400 Phoenix Contact	HC-KIT-A-B06-SM0001	0
0936060452 Woodhead - Molex	7832.4700.0 + 2000.3001.0	0
1416349 Phoenix Contact	STA CONNECTOR SET B16 METAL HOUS	0
0936030088 Woodhead - Molex	COMPLETE SET WITH CABLE GLAND	0
1409697 Phoenix Contact	HC-KIT-B10-R01	0
09573680510000 HARTING	HAN 3A M RECEPTACLE AC SET W JA	10
1103168-1 TE Connectivity AMP Connectors	SET HB.48.AG/HE.24	0
10000005230 HARTING	KIT HAN EASY LOCK F. HAN 24B	0
10200030003PG HARTING	CONN ASSY TOP ENTRY 3+GND SZ3A	0
6104401055001 HARTING	CONN ASSY 5POS	0
73101000035 HARTING	HAN-KIT - 108DD METAL,108+GND, D	0
1607394 Phoenix Contact	CONN FRAME AND INSERT 15+GND	2
0936030086 Woodhead - Molex	COMPLETE SET WITH CABLE GLAND	0
1641581 Phoenix Contact	CONN ASSY TOP ENTRY 3POS SZD7	0
1802470000 Weidmuller	CONN ASSY TOP ENTRY 3+GND SZ1	0
10220030004 HARTING	HAN-YELLOCK 10 KIT 5+GND - ANGLE	0
10330240000PG HARTING	CONN ASSY SIDE ENTRY 24+GND 24B	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