Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
1663239 Phoenix Contact	CONTACT H.D. CRIMP PIN 16AWG	58300
09322006225 HARTING	HAN C FEMALE CONTACT AWG 14 (2.5	25
09330006105 HARTING	CONTACT H.D. CRIMP PIN 18AWG	2678
T2020011002-000 TE Connectivity AMP Connectors	DDM-0.3	192
T2070012033-000 TE Connectivity AMP Connectors	DAF-33	1368
0936010520 Woodhead - Molex	S-M PN2 PNEUMATIC CONN. ADT 2 CN	0
09110006233 HARTING	CONTACT H.D. CRIMP SOCKET 3AWG	131
1651600000 Weidmuller	CONTACT H.D. CRIMP SOCKET 16AWG	170010
VN0201001312 Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	300
N01 060 0004 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 4AWG	0
09140006111 HARTING	CONTACT H.D. CRIMP/SOLDER PIN	18
T2400001100-000 TE Connectivity AMP Connectors	CSM-10	412
1435760000 Weidmuller	CONTACT (INDUSTRY PLUG-IN CONNEC	276
T2050002016-000 TE Connectivity AMP Connectors	CNF-16	114
4-1105151-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SOCKET 7AWG	0
T2030012002-000 TE Connectivity AMP Connectors	DEF-0.3	200
3-1105301-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SKT 15.5AWG	0
11050006103 HARTING	CONTACT H.D. CRIMP PIN 18AWG	332
N020366137002 Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET	135
T2196502070-001 TE Connectivity AMP Connectors	T2196502070-001	24

Heavy Duty Connectors - Contacts

1. Overview

Heavy duty connectors - contacts are specialized electrical components designed to establish reliable conductive pathways in high-current, high-voltage, or harsh-environment applications. These contacts serve as critical interface points in power transmission systems, industrial machinery, and transportation infrastructure. Their importance continues to grow with advancements in electrification, renewable energy systems, and automated manufacturing processes.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Bolted Contacts	High mechanical stability, screw-terminal connections	Power distribution panels, heavy machinery
Blade Contacts	Quick-insert design with positive lock mechanism	Automotive systems, battery packs
Circular Contacts	360 rotational connectivity	Rotary unions, wind turbines
Printed Circuit Contacts	Surface-mount compatible with PCB integration	Industrial control systems, automation equipment

3. Structure and Components

Typical construction includes:

Contact body: Copper alloys (C18150, C11000) or aluminum alloys
Contact surface: Silver-plated or tin-coated for enhanced conductivity
Insulation housing: Thermoplastic (PBT) or thermoset materials
Locking mechanism: Bayonet, threaded, or spring-loaded systems
Environmental seals: IP65-rated gaskets and O-rings

Modular designs often incorporate replaceable contact inserts and integrated cooling channels.

4. Key Technical Specifications

Parameter	Typical Range	Importance
Current Rating	100A - 5000A	Determines power transmission capacity
Voltage Rating	600V - 15kV	Ensures dielectric safety
Contact Resistance	<0.1m - 0.5m	Impacts thermal performance
Temperature Range	-55 C to +150 C	Defines operational envelope
Insertion Force	50N - 200N	Affects mating durability

5. Application Fields

Energy: Power generation equipment, grid infrastructure
Transportation: Electric vehicles, rail systems, marine propulsion
Industrial: CNC machinery, welding robots, factory automation
Renewables: Wind turbine converters, solar inverters
Military/Aerospace: Avionics systems, defense equipment

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
TE Connectivity	XD Connector System	1500A rating, quick-make design
Amphenol Industrial	MAXRAD High Power	IP67 protection, 3-phase configuration
Delphi Automotive	EVP High Voltage Connector	800V capability, fault current protection

7. Selection Recommendations

Key considerations:

Current/voltage requirements with 20% safety margin
Environmental protection (IP rating, corrosion resistance)
Mating cycle requirements (1000-10,000+ cycles)
Compliance with standards (IEC 60999, UL 486A-B)
Thermal derating for ambient temperatures >40 C

Case study: For wind turbine generator connections, specify silver-plated contacts with IP65 sealing and vibration damping features.

8. Industry Trends

Current developments include:

Miniaturization while maintaining high current density
Integration with smart monitoring (IoT-enabled contacts)
Advanced coating technologies (graphene-enhanced surfaces)
Increased focus on recyclable materials
Hybrid designs combining power and signal transmission