Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
T2060001035-000 TE Connectivity AMP Connectors	CHM-35	0
09110006268 HARTING	HAN HC MODULAR 650 FEMALE CONTAC	0
1663695 Phoenix Contact	CONTACT H.D. CRIMP SOCKET 13AWG	105100
11000009509 HARTING	CONTACT H.D. CRIMP PIN 10AWG	100
44423245 LAPP	CONN CNT SLV PIN 8MM 6AWG	50
0936010046 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 18AWG	0
T2030001015-000 TE Connectivity AMP Connectors	CEM-1.5	349
09140006403 HARTING	CONTACTS FOR TUBE INNER DIAMETER	10
09320006208 HARTING	CONTACT H.D. CRIMP SOCKET 10AWG	1399
T2020002008-000 TE Connectivity AMP Connectors	CDF-0.75	133
09140007354 HARTING	PNEUM. CONTACT METAL OD 4MM MALE	15
T2050001035-000 TE Connectivity AMP Connectors	CNM-35	158
09330006117 HARTING	CONTACT H.D. CRIMP PIN 22-26AWG	43
09110006263 HARTING	CONTACT H.D. CRIMP SOCKET 4/0AWG	4
09110006162 HARTING	CONTACT H.D. CRIMP PIN 3/0AWG	0
09110006121 HARTING	CONTACT H.D. CRIMP PIN 3AWG	46
T2192502035-000 TE Connectivity AMP Connectors	T2192502035-000	0
09110006150 HARTING	HAN TC200 FEMALE CONTACT 16MM	0
09150006205 HARTING	CONTACT H.D. CRIMP SOCKET 18AWG	1999
09150006127 HARTING	CONTACT H.D. CRIMP PIN 22-26AWG	0

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