Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120062666 HARTING	INSERT MALE 4+2POS+1GND SCREW	10
C146 10A006 500 12 Tuchel / Amphenol	INSERT MALE 4+2POS+1GND CRIMP	0
09330162612 HARTING	INSERT MALE 16POS+1GND CRIMP	8
09338062603 HARTING	HAN HIGH TEMP 6E SCREW MALE	10
09330162788 HARTING	HAN 32ES - 16ES PRESS FEMALE INS	0
09340032616 HARTING	INSERT MALE 3+2POS+1GND PUSH IN	18
1211300000 Weidmuller	INSERT FEMALE 24POS+1GND SCREW	94114
T2050102201-000 TE Connectivity AMP Connectors	INSERT FML 10POS+1GND HEE-010-F	29
09210644611 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	2
0936010115 Woodhead - Molex	72P + PE MALE INSERT 10A 250V/UL	10
10431000 LAPP	CONN INSERT HA4 MALE	523
1648157 Phoenix Contact	INSERT MALE 6POS+1GND CRIMP	10
0936010530 Woodhead - Molex	S-M 40/4 M INS CRP 4P 40A 830V	0
T2020402101-000 TE Connectivity AMP Connectors	INSERT MALE 40POS+1GND CRIMP	8
09120042701 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
09332102648 HARTING	HAN 10E MALE ES PRESS INSERT, HI	14
C146 10B057 000 6 Tuchel / Amphenol	INSERT FEMALE 57POS+1GND CRIMP	0
C146 10B005 500 12 Tuchel / Amphenol	INSERT FEMALE 5POS+1GND CRIMP	0
2-1103102-3 TE Connectivity AMP Connectors	INSERT MALE 7POS+1GND CRIMP	0
1414359 Phoenix Contact	MODULE FEMALE 3POS CRIMP	24240

Heavy Duty Connectors - Inserts, Modules

1. Overview

Heavy duty connectors inserts and modules are specialized electromechanical components designed to establish robust electrical connections in demanding environments. These systems provide modular solutions for power transmission, signal routing, and data communication in industrial and infrastructure applications. Their importance lies in enabling reliable connectivity in harsh conditions involving high currents, extreme temperatures, vibration, and contamination.

2. Major Types & Functional Classification

Type	Functional Features	Application Examples
Modular Insert Systems	Customizable contact arrangements, hot-swappable design	Industrial control cabinets, automated machinery
High-Power Modules	Rated for >100A currents, integrated cooling channels	Electric vehicle charging stations, factory automation
Signal Transmission Inserts	Shielded contacts for <10Gbps data rates	Smart grid monitoring systems, robotics
Hybrid Power-Signal Modules	Combined power and fiber optic transmission	Wind turbine pitch control, mining equipment

3. Structural Composition

Typical construction includes:

Durable thermoplastic or metal housing (IP65-IP69K rating)
Copper alloy contact elements with gold/silver plating
Integrated locking mechanisms (screw, bayonet, or push-pull)
Modular frame supporting mixed contact types
Environmental seals (EPDM or silicone rubber)

4. Key Technical Specifications

Parameter	Importance
Current Rating (10-2000A)	Determines power transmission capacity
Voltage Range (24V-10kV)	Defines insulation requirements
Contact Resistance (<1m )	Impacts energy efficiency and heat generation
Operating Temperature (-40 C to +125 C)	Dictates environmental suitability
Mating Cycles (500-10,000)	Determines service life and reliability

5. Application Fields

Primary industries include:

Industrial Automation: PLC systems, CNC machines
Energy: Wind turbines, solar inverters
Transportation: Rail traction systems, e-mobility charging
Heavy Machinery: Excavators, mining equipment
Marine: Offshore platform systems, shipboard power

6. Leading Manufacturers & Products

Manufacturer	Representative Product
TE Connectivity	DEUTSCH HC Series High-Current Connectors
Amphenol Industrial	MAXdur Hybrid Power/Sig nal Modules
Phoenix Contact	Heavycon Modular Insert Systems
Weidm ller	HA-Modular Hybrid Connection Technology

7. Selection Guidelines

Key considerations:

Calculate maximum current/voltage requirements with safety margins
Assess environmental factors (temperature, vibration, chemicals)
Verify IP rating for ingress protection
Evaluate mating cycle requirements
Check industry-specific certifications (UL, CSA, IEC standards)
Consider modular expandability for future upgrades

8. Industry Trends

Current development trends include:

Miniaturization while maintaining high current capacity
Integration of smart sensing capabilities
Adoption of fiber-optic hybrid transmission
Increased use of corrosion-resistant composite materials
Development of quick-connect systems for reduced downtime

Market growth is driven by electrification in industrial sectors and the rise of renewable energy systems, with a projected CAGR of 6.2% through 2028 (Source: MarketsandMarkets).