Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09340102602 HARTING	INSERT MALE 10+2POS+1GND CRIMP	0
C146B20001G8 Tuchel / Amphenol	MODULE FEMALE 20POS CRIMP	0
2-1103033-3 TE Connectivity AMP Connectors	INSERT FEMALE 64POS+1GND CRIMP	159
09150043113 HARTING	INSERT FEMALE 4POS CRIMP	7
09330104636 HARTING	INSERT MALE 10P+1GND TERM BLOCK	0
09140033002 HARTING	MODULE MALE 3POS CRIMP	49
C146 B05 100 G8 Tuchel / Amphenol	MODULE FEMALE 4POS CRIMP	0
2-1103415-3 TE Connectivity AMP Connectors	INSERT FEMALE 10POS+1GND CRIMP	0
19410202601 HARTING	HAN ECO 20E-M-S	13
C146 10B002 900 15 Tuchel / Amphenol	MODULE W/O CONTACTS FEMALE 2POS	0
0936010275 Woodhead - Molex	16B SEST M INS SCRW 16P 16A 500V	47
09140273013 HARTING	SHIELDED MODULE 27PIN MALE INSER	9
1648115 Phoenix Contact	INSERT MALE 6POS SCREW	147182
09100123105 HARTING	1A 12PIN FEMALE CRIMP INSERT FOR	38
09332162702 HARTING	HAN 16E HMC-F-CRIMP	14
0936010512 Woodhead - Molex	S-M 40/2A M INS SCRAX 2X40A 1KV	0
19410282701 HARTING	HAN ECO 28E-F-S	13
09120083101 HARTING	INSERT FEMALE 8POS+1GND CRIMP	38
1407728 Phoenix Contact	HC-B 06-I-PT-M	10144
0512041200 Woodhead - Molex	INSERT W/O CONTACTS FEMALE 12POS	290

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).