Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
09330006221 HARTING	CONTACT H.D. CRIMP SOCKET 12AWG	0
09110006230 HARTING	CONTACT H.D. SOCKET	20
0936010182 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 12AWG	0
1676802 Phoenix Contact	CONTACT H.D. CRIMP/SOLDER PIN	0
09140006406 HARTING	CONTACTS FOR TUBE INNER DIAMETER	1
0936010171 Woodhead - Molex	CONTACT H.D. CRIMP SKT 22-26AWG	0
2637460000 Weidmuller	HDC MODUPLUG, 3MM FEMALE, PNEUMA	2080
T2020002005-000 TE Connectivity AMP Connectors	CDF-0.5	185
T2040002025-000 TE Connectivity AMP Connectors	CMF-2.5	183
5-1105051-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SKT 13.5AWG	956
09930006264 HARTING	HAN S CRIMP CONTACT, FEMALE, ANG	100
09150016101 HARTING	HAN COAX ETCS CONTACT MALE	20
09322006229 HARTING	HAN C FEMALE CONTACT AWG 12 (4MM	23
TN0201001302 Tuchel / Amphenol	CONTACT H.D. CRIMP SKT 24-28AWG	0
09110006284 HARTING	HAN HC MODULAR 250 FEMALE CRIMP	0
4-1105150-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP PIN 7AWG	75
4-1105050-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP PIN 15.5AWG	3800
09350006106 HARTING	CONTACT H.D. CRIMP PIN 16AWG	75
44423258 LAPP	CONN CNT SLV SKT 4MM 10AWG	300
1676815 Phoenix Contact	CONTACT H.D. CRIMP/SOLDER SOCKET	35

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