Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
11192000 LAPP	CONN CNT GLD PIN 2.5MM 20AWG	500
1674859 Phoenix Contact	CONTACT H.D. CRIMP SOCKET 20AWG	90
11190000 LAPP	CONN CNT SLV PIN 2.5MM 20AWG	1200
1651700000 Weidmuller	CONTACT H.D. CRIMP SOCKET 100/PK	1
09110006285 HARTING	HAN HC MODULAR 250 FEMALE CRIMP	0
09110006220 HARTING	CONTACT H.D. CRIMP SOCKET 3AWG	0
T2192502050-000 TE Connectivity AMP Connectors	T2192502050-000	0
11190200 LAPP	CONN CNT SLV PIN 2.5MM 16AWG	1000
1674930 Phoenix Contact	CONTACT H.D. CRIMP SOCKET 16AWG	172
T2192501050-000 TE Connectivity AMP Connectors	T2192501050-000	0
09152006126 HARTING	CONTACT H.D. CRIMP PIN 14AWG	4
T2030012025-000 TE Connectivity AMP Connectors	DEF-2.5	190
0936010062 Woodhead - Molex	CONTACT H.D. CRIMP PIN 14AWG	0
1-1105101-2 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SOCKET 20AWG	0
09150006302 HARTING	CONTACT H.D. CRIMP PIN 18AWG	1432
T2196502120-001 TE Connectivity AMP Connectors	T2196502120-001	24
0936010184 Woodhead - Molex	CONTACT H.D. CRIMP PIN 20AWG	0
5-1105050-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP PIN 13.5AWG	0
1676750 Phoenix Contact	CONTACT H.D. PIN MODULE	10205
T2030012015-000 TE Connectivity AMP Connectors	DEF-1.5	6001

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