Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010296 Woodhead - Molex	S-EC INS.16P MALE CRIMP TERM.17-	0
09140012768 HARTING	MODULE FEMALE 1POS SCREW	0
10191000 LAPP	CONN INSERT HBE6 FEMALE	99
09210403101 HARTING	INSERT FEMALE 40POS+1GND CRIMP	5
10196100 LAPP	CONN INSERT HBE24 MALE W/O WP	44
0936010273 Woodhead - Molex	16P + PE MALE INSERT 16A 500V/UL	105
09330242702 HARTING	INSERT FEMALE 24POS+1GND CRIMP	5
0936010125 Woodhead - Molex	3P MALE INSERT 10A 250V, UL600V,	0
C146 B03 001 E8 Tuchel / Amphenol	MODULE FEMALE 3POS CRIMP	0
19410102701 HARTING	HAN-ECO 10E-F-S	15
09200042711 HARTING	INSERT FEMALE 4POS+1GND SCREW	272
T2111032301-000 TE Connectivity AMP Connectors	MOD PNEUMATIC MALE 3POS HMN-PA3	3
1853476 Phoenix Contact	INSERT FEMALE 6POS SCREW	33
0936010204 Woodhead - Molex	S-EP INSERT 6P FEMALE PUSH-IN TE	23
1018960000 Weidmuller	INSERT FEMALE 32POS+1GND CRIMP	0
09120173101 HARTING	INSERT FEMALE 17POS CRIMP	19
1424224 Phoenix Contact	CONN INSERT FEMALE 6POS	5217
0936010205 Woodhead - Molex	6P + PE MALE INSERT 16A 500V/UL	1
09360062601 HARTING	HAN 6EX-M-S	0
T2111062201-000 TE Connectivity AMP Connectors	MODULE FEMALE 6POS HMN-006-F	89

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).