Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09330162726 HARTING	INSERT FEMALE 16POS+1GND PUSH IN	5
09160243001 HARTING	INSERT MALE 24POS+1GND CRIMP	127
HE-010-MS TE Connectivity AMP Connectors	INSERT MALE 10POS CLAMP	97
09320103101 HARTING	INSERT FEMALE 10POS+1GND CRIMP	9
C146 10A002 900 15 Tuchel / Amphenol	MODULE W/O CONTACTS MALE 2POS	0
1221200000 Weidmuller	INSERT FEMALE 24POS+1GND SCREW	119
09210402701 HARTING	INSERT FEMALE 40P+1GND WIRE WRAP	3
1014080000 Weidmuller	HDC CM BUS SV GCA M	35
T2111122201-000 TE Connectivity AMP Connectors	MODULE FEMALE 12POS HMN-012-F	33
0936010093 Woodhead - Molex	24P + PE FEMALE INSERT 10A 250V/	3
09330062616 HARTING	INSERT MALE 6POS+1GND PUSH IN	8
1103018-1 TE Connectivity AMP Connectors	MDL2.3+4.STI.C	18
1852833 Phoenix Contact	INSERT MALE 8POS SOLDER	1216
11051052803 HARTING	HAN YELLOCK MULTIPLIER 3:2	26
19410012700 HARTING	MODULE FEMALE 1POS SCREW	2
HMN-D2-MC TE Connectivity AMP Connectors	MODULE MALE 2POS HMN-D2-MC	80
19410142701 HARTING	HAN-ECO 14E-F-S	12
09120082734 HARTING	INSERT FEMALE 8POS PUSH IN LOCK	0
09140013031 HARTING	MODULE MALE 1POS CRIMP/SCREW	58
1498900000 Weidmuller	INSERT FEMALE 6POS+1GND SCREW	14130

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).