Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
09150006305 HARTING	CONTACT H.D. CRIMP PIN 18AWG	63
09330006180 HARTING	CONTACT H.D. CRIMP PIN	220
09140007453 HARTING	PNEUM. CONTACT METAL OD3MM FEMAL	20
09322006228 HARTING	HAN C FEMALE CONTACT AWG 10 (6MM	25
09140006215 HARTING	CONTACT H.D. SOLDER SOCKET	24
1663530 Phoenix Contact	CONTACT H.D. SOCKET MODULE	3010
09110006290 HARTING	HAN HC250 PE FEMALE CONTACT 16MM	0
1121560C LAPP	CONN CNT SLV SKT 3.6MM 14AWG	614
4-1105100-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP PIN 13.5AWG	0
VN0201600251C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	378
T2196502185-001 TE Connectivity AMP Connectors	T2196502185-001	12
09320006295 HARTING	CONTACT H.D. SOLDER SOCKET	0
09330006207 HARTING	CONTACT H.D. CRIMP SOCKET 12AWG	327
0936010061 Woodhead - Molex	CONTACT H.D. CRIMP PIN 14AWG	860
44423244 LAPP	CONN CNT SLV PIN 8MM 2AWG	50
11195300 LAPP	CONN CNT SLV SKT 2.5MM 14AWG	970
09110006256 HARTING	CONTACT H.D. AXIAL SCREW SOCKET	0
T2060001050-000 TE Connectivity AMP Connectors	CHM-50	0
09110006112 HARTING	CONTACT H.D. AXL SCRW PIN 4-6AWG	20
20100013222 HARTING	CONTACT H.D. CRIMP SOCKET	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