Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
1602996 Phoenix Contact	CONTACT H.D. CRIMP PIN 18-20AWG	11
1663488 Phoenix Contact	CONTACT H.D. PIN MODULE	50
0936010174 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 20AWG	0
20100015211 HARTING	CONTACT H.D. CRIMP	20
T2020012008-000 TE Connectivity AMP Connectors	DDF-0.75	190
0936010178 Woodhead - Molex	CONTACT H.D. CRIMP SOCKET 16AWG	500
09110006135 HARTING	CONTACT H.D. CRIMP PIN 2AWG	52
1663857 Phoenix Contact	CONTACT H.D. CRIMP PIN 18AWG	0
TN01 016 0015 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 16-20AWG	0
VN0101001312 Tuchel / Amphenol	CONTACT H.D. CRIMP PINS	100
09330006121 HARTING	CONTACT H.D. CRIMP PIN 20AWG	985
T2030001008-000 TE Connectivity AMP Connectors	CEM-0.75	456
2637490000 Weidmuller	HDC Moduplug,1.6mm Female	2060
T2020012010-000 TE Connectivity AMP Connectors	DDF-1.0	90
09150006304 HARTING	CONTACT H.D. CRIMP PIN 22-26AWG	49
09332006218 HARTING	HAN E HMC FEMALE CONTACT AU AWG	103
09150006125 HARTING	CONTACT H.D. CRIMP PIN 18AWG	108
09150006290 HARTING	CONTACT H.D. SOLDER SOCKET	50
09350006203 HARTING	CONTACT H.D. CRIMP SOCKET 20AWG	400
13162500 LAPP	CONN CNT GLD PIN 1.6MM 26-22AWG	150

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