Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1429360000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	6026
09140023141 HARTING	MODULE FEMALE 2POS CRIMP	238
09330102691 HARTING	INSERT MALE 10POS+1GND SCREW	5
09150083013 HARTING	INSERT MALE 8POS CRIMP	103
09140012633 HARTING	HAN PE-MODULE MALE AXIAL 16-35QM	0
09200042634 HARTING	INSERT MALE 4POS+1GND PUSH IN	7
1983770000 Weidmuller	MODULE FEMALE 4POS CRIMP	0
09161083101 HARTING	INSERT FEMALE 108POS+1GND CRIMP	102
09330242611 HARTING	INSERT MALE 24POS+1GND SCREW	6
C146G02024G8 Tuchel / Amphenol	MODULE PNEUMATIC MALE 2POS CRIMP	0
09162243001 HARTING	HAN 24DD-HMC-M-C	1
09120042611 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	0
0936010081 Woodhead - Molex	CRIMP TYPE INSERT FEMALE	0
1585210 Phoenix Contact	INSERT MALE 3POS+1GND SCREW	30
09330104629 HARTING	INSERT MALE 10P+1GND TERM BLOCK	7
09110012775 HARTING	MODULE FEMALE 1POS SCREW	1
C14610A0240001 Tuchel / Amphenol	INSERT MALE 24POS+1GND CRIMP	0
10421000 LAPP	CONN INSERT HA3 FEMALE	140
C14610B0101021 Tuchel / Amphenol	INSERT FEMALE 10POS+1GND SCREW	23
1648173 Phoenix Contact	INSERT MALE 10POS SCREW	49297

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).