Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
0936010460 Woodhead - Molex	200A MALE CRIMP CONT 70MM	0
0936010499 Woodhead - Molex	S-M CX/75 F CONN 1P+SHLD 75 OHM	0
VN02 025 0039 1C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 100PCS	0
2-1105351-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SOCKET	0
09150005202 HARTING	HAN D FEMALE CONTACT AWG 18 (1MM	0
09330006112 HARTING	CONTACT H.D. CRIMP PIN 12AWG	0
1-1108756-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP SKT 15.5AWG	0
T2090002201-004 TE Connectivity AMP Connectors	T2090002201-004	0
09332006215 HARTING	HAN E FEMALE CONTACT 0.75MM, GOL	0
09110006226 HARTING	CONTACT H.D. SOCKET	0
4-1108757-1 TE Connectivity AMP Connectors	CONTACT H.D. CRIMP PIN 10AWG	0
09330005107 HARTING	HAN E MALE CONTACT AWG 12 (4MM2)	0
11050006125 HARTING	HAN-YELLOCK MALE CONTACT AWG 16	0
0936010545 Woodhead - Molex	S-M CX/8 F CONN 4P+SHLD 5A	0
09332006180 HARTING	HAN E HMC TWIN CONTACT M FOR PCB	0
1650343-1 TE Connectivity AMP Connectors	711-0094-02107=CONTACT,PIN,#8,	0
1651630000 Weidmuller	CONTACT H.D. CRIMP PIN 100/PK	8
T2090002101-002 TE Connectivity AMP Connectors	T2090002101-002	0
0936010075 Woodhead - Molex	S-Q7/PCB SILVER 7P PCB ADAPT	0
0936010423 Woodhead - Molex	CONTACT H.D. CRIMP PIN 10AWG	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