Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
09110006142 HARTING	CONTACT H.D. CRIMP PIN 2/0AWG	11
1663352 Phoenix Contact	CONTACT H.D. CRIMP PIN 18AWG	12
09330006109 HARTING	CONTACT H.D. CRIMP PIN 18AWG	389
09110006172 HARTING	HAN HC MODULAR 350 MALE PE CRIMP	0
09110006168 HARTING	HAN HC MODULAR 650 MALE CONTACT	0
N01 060 0007 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 6AWG	0
1200600000 Weidmuller	CONTACT H.D. CRIMP PIN 100/PK	17
09330006162 HARTING	CONTACT H.D. CRIMP PIN 20AWG	33
1682290000 Weidmuller	CONTACT H.D. CRIMP SOCKET 10AWG	1097
T2030012008-000 TE Connectivity AMP Connectors	DEF-0.75	183
09330006111 HARTING	CONTACT H.D. CRIMP PIN 14AWG	1057
0936010410 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 12AWG	1
09110006228 HARTING	CONTACT H.D. CRIMP SOCKET 1/0AWG	0
VN0202500311C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	9254
09330006295 HARTING	CONTACT H.D. SOCKET	0
44423255 LAPP	CONN CNT SLV SKT 4MM 16AWG	300
T2196501070-001 TE Connectivity AMP Connectors	T2196501070-001	24
09330006163 HARTING	CONTACT H.D. CRIMP PIN 22-26AWG	165
09338006220 HARTING	HAN E FEMALE CONTACT AWG 20 (0.5	200
09332006117 HARTING	CONTACT H.D. CRIMP PIN 22-26AWG	119

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