Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09360463101 HARTING	HAN 46EX-F-C	0
C146A03801E8 Tuchel / Amphenol	MODULE MALE 3POS CRIMP	49
1648241 Phoenix Contact	INSERT FEMALE 16POS SCREW	19270
T2193502120-000 TE Connectivity AMP Connectors	T2193502120-000	0
09338102603 HARTING	HAN HIGH TEMP 10E SCREW MALE	0
1023260000 Weidmuller	INSERT MALE 4+8POS+1GND SCREW	0
1428840000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	9543
0936010149 Woodhead - Molex	16P + PE MALE INSERT 16A 250V/UL	10
1407729 Phoenix Contact	HC-B 10-I-PT-F	15
09330162626 HARTING	INSERT MALE 16POS+1GND PUSH IN	5
09200042611 HARTING	INSERT MALE 4POS+1GND SCREW	230
09140033052 HARTING	HAN-ECO MODULAR GUIDING PE MODUL	37
09140022751 HARTING	MODULE FEMALE 2POS SCREW	40
C146C05801E8 Tuchel / Amphenol	MODULE FEMALE 5POS CRIMP	0
1772311 Phoenix Contact	INSERT FEMALE 15POS CRIMP	0
T2030242101-000 TE Connectivity AMP Connectors	INSERT MALE 24POS+1GND HDD-024-M	8
09140084720 HARTING	HAN-MOD RJ45 PRELINK SET 8P	3
T2032162101-000 TE Connectivity AMP Connectors	INSRT 108P+1GD HDD-108-M 109-216	44
10431500 LAPP	CONN INSERT HQ5 MALE	0
1103427-2 TE Connectivity AMP Connectors	INSERT FEMALE 4POS CRIMP	0

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).