Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
HMN-004-M TE Connectivity AMP Connectors	MODULE MALE 4POS HMN-004-M	190
C146G01024G8 Tuchel / Amphenol	MODULE PNEUMATIC MALE 1POS CRIMP	0
09120063141 HARTING	INSERT FEMALE 4+2POS+1GND CRIMP	113
09120033021 HARTING	INSERT RJ45 MALE 8P8C IDC	43
1873540000 Weidmuller	INSERT FEMALE 10POS+1GND PUSH IN	1012
1-1103638-1 TE Connectivity AMP Connectors	INSERT MALE 16POS+1GND SCREW	11
HEEE-040-F TE Connectivity AMP Connectors	INSERT FML 40POS+1GND HEEE-040-F	56
T2111063201-000 TE Connectivity AMP Connectors	MODULE FEMALE 6POS HMN-006-PF	0
09320123001 HARTING	INSERT MALE 12+2POS+1GND CRIMP	1
1-1103417-1 TE Connectivity AMP Connectors	INSERT FEMALE 16POS+1GND SCREW	0
09120062794 HARTING	INSERT FEMALE 4+2POS+1GND SCREW	18
1950290000 Weidmuller	MOD RJ45 FEMALE 8P8C+4PWR CRIMP	415
1428870000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	2037
1650820000 Weidmuller	INSERT FEMALE 25POS+1GND CRIMP	20
09100123100 HARTING	1A 12PIN FEMALE CRIMP INSERT WIT	37
T2030162201-000 TE Connectivity AMP Connectors	INSERT FEMALE 16POS+1GND CRIMP	88
09330164725 HARTING	INSERT FMALE 16P+1GND TERM BLOCK	0
09200042733 HARTING	INSERT FEMALE 4POS+1GND PUSH IN	77
1585236 Phoenix Contact	INSERT MALE 4POS+1GND SCREW	451
1674765 Phoenix Contact	INSERT MALE 108POS+1GND 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).