Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
0936010485 Woodhead - Molex	S-M PN2 F PNEUM. CNT D 6 TUBE W/	0
VN0204000101C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 16AWG	0
09110006128 HARTING	CONTACT H.D. CRIMP PIN 1/0AWG	18
0936010057 Woodhead - Molex	CONTACT H.D. CRIMP PIN 18AWG	1434
09150006403 HARTING	CONTACT H.D. CRIMP SOCKET 20AWG	190
09110006217 HARTING	FEMALE CONTACT M12 FOR MATING TO	0
13163400 LAPP	CONN CNT SLV SKT 1.6MM 14AWG	484
09150006206 HARTING	CONTACT H.D. CRIMP SOCKET 14AWG	0
T2400002160-000 TE Connectivity AMP Connectors	CSF-16	21
09338006202 HARTING	HAN E FEMALE CONTACT AWG 14 (2.5	200
09330006123 HARTING	CONTACT H.D. CRIMP PIN 14AWG	99
1674969 Phoenix Contact	CONTACT H.D. CRIMP SKT 22-24AWG	865186
09152006125 HARTING	CONTACT H.D. CRIMP PIN 18AWG	221
09150006297 HARTING	HAN D DOUBLE FEMALE CONTACT FOR	0
09110006231 HARTING	CONTACT H.D. CRIMP SOCKET 8AWG	411
1674846 Phoenix Contact	CONTACT H.D. CRIMP SOCKET 12AWG	100
T2060002025-000 TE Connectivity AMP Connectors	CHF-25	0
T2196501150-001 TE Connectivity AMP Connectors	T2196501150-001	23
09310006205 HARTING	HAN HSB FEMALE CONTACT AWG 14 (2	100
T2196501095-001 TE Connectivity AMP Connectors	T2196501095-001	23

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