Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
VN0202500431 Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 100PCS	0
VN0201600262C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 100PCS	0
VN0201600271C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	380
VN0103600031C Tuchel / Amphenol	CONTACT H.D. CRIMP PINS	310
VN0204000101C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 16AWG	0
VN01 016 0015 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 100PCS	500
VN0204000111C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 14AWG	0
TN0102500431 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 12AWG	0
VN0104000111C Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 14AWG	0
TN02 016 0016 1 Tuchel / Amphenol	CONTACT H.D. CRIMP SKT 14-16AWG	0
17D M53740 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN	0
VN0201600281C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	99
N01 100 6003 001 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 3/0AWG	0
VN01 016 0016 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 100PCS	400
VN0202500291C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKET 100PCS	0
VN0101600241C Tuchel / Amphenol	CONTACT H.D. CRIMP PINS	2234
VN0203600031C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	100
N01 060 0007 1 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 6AWG	0
VN0202500311C Tuchel / Amphenol	CONTACT H.D. CRIMP SOCKETS	9254
N01 100 6002 001 Tuchel / Amphenol	CONTACT H.D. CRIMP PIN 2/0AWG	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