Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1896820000 Weidmuller	INSERT FEMALE 16POS+1GND PUSH IN	10
09140123002 HARTING	HAN DD 12PIN MODULE MALE CRIMP	77
1102194-1 TE Connectivity AMP Connectors	INSERT FEMALE 5POS+1GND CRIMP	314
19410282601 HARTING	HAN ECO 28E-M-S	17
1108812-1 TE Connectivity AMP Connectors	INSERT FEMALE/MALE 8P8C IDC	0
C14610A0720009 Tuchel / Amphenol	INSERT MALE 72POS+1GND CRIMP	0
09140044513 HARTING	MODULE FEMALE 4POS CRIMP/SOLDER	5
09365062701 HARTING	HAN 6E EX FEMALE SCREW TERMINAL	5
09140124512 HARTING	MODULE FEMALE 12POS CRIMP	26
1414356 Phoenix Contact	MODULE MALE 17POS CRIMP	121548
2120325-1 TE Connectivity AMP Connectors	TAB CONNECTOR	0
09120042601 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	30
HA-016-MC TE Connectivity AMP Connectors	INSERT MALE 16+1GND CRIMP	139
C146H01034G8 Tuchel / Amphenol	MOD PNEUMATIC FEMALE 1POS CRIMP	0
1651160000 Weidmuller	INSERT FEMALE 24POS+1GND CRIMP	1842
1674752 Phoenix Contact	INSERT FEMALE 108POS+1GND CRIMP	0
1023220000 Weidmuller	INSERT MALE 4+0POS+1GND SCREW	1025
1003190000 Weidmuller	INSERT MALE 7POS+1GND CRIMP	224
1429340000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	6040
2592220000 Weidmuller	Module, Plug insert, TIA-568A	4

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).