Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
0936010164 Woodhead - Molex	CONTACT H.D. CRIMP PIN 18AWG	500
1004360 Phoenix Contact	CONTACT CRIMP PIN 22-17AWG	200
09152006127 HARTING	HAN D M CRIMP CONTACT 0,14-0,37M	0
T2090012201-003 TE Connectivity AMP Connectors	T2090012201-003	121
1663679 Phoenix Contact	CONTACT H.D. CRIMP SOCKET 16AWG	3976900
0936010170 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 18AWG	0
TN02 016 0016 1 Tuchel / Amphenol	CONTACT H.D. CRIMP SKT 14-16AWG	0
T2050002010-000 TE Connectivity AMP Connectors	CNF-10	173
09110006130 HARTING	CONTACT H.D. PIN	0
T2020012015-000 TE Connectivity AMP Connectors	DDF-1.5	99
1004366 Phoenix Contact	CONTACT CRIMP SKT 16-14AWG	100
T2193502070-000 TE Connectivity AMP Connectors	T2193502070-000	0
09310006103 HARTING	HAN HSB MALE CONTACT AWG 8 (10MM	100
T2020001008-000 TE Connectivity AMP Connectors	CDM-0.75	74
T2090002101-003 TE Connectivity AMP Connectors	PNEU-C-M4.0	38
09140006221 HARTING	CONTACT H.D. CRIMP/SOLDER SOCKET	12
17D M53740 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN	0
VN0201600281C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	99
09320006108 HARTING	CONTACT H.D. CRIMP PIN 10AWG	556
2637430000 Weidmuller	HDC MODUPLUG, 4MM FEMALE, PNEUMA	2080

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