Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1873530000 Weidmuller	INSERT MALE 6POS+1GND PUSH IN	2296
09320323001 HARTING	INSERT MALE 32POS+1GND CRIMP	15
09320643101 HARTING	INSERT FEMALE 64POS+1GND CRIMP	5
0936010244 Woodhead - Molex	10P + PE MALE INSERT 16A 500V/UL	18
1414355 Phoenix Contact	MODULE FEMALE 12POS CRIMP	66403
09210404701 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	4
C14610A0160021 Tuchel / Amphenol	INSERT MALE 16POS+1GND SCREW	0
09120033015 HARTING	HAN-BRID RJ45C-M-RJ INDUSTRIAL 1	0
0936010445 Woodhead - Molex	S-QD8/0 16A 500V SP+PE FEMALE IN	45
0936010548 Woodhead - Molex	S-M D/9 M D-SUB 9P 5A 50V	0
09110013101 HARTING	MODULE FEMALE 1POS CRIMP	5
1584062 Phoenix Contact	INSERT FEMALE 42POS+1GND CRIMP	9
10195000 LAPP	CONN INSERT HBE16 FEMALE	65
1605572 Phoenix Contact	INSERT FEMALE 16POS IDC	1
09330064626 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
T2111122101-000 TE Connectivity AMP Connectors	MODULE MALE 12POS HMN-012-M	0
2592250000 Weidmuller	HDC MRJ45 8PLUG MC	4
09210402601 HARTING	INSERT MALE 40POS+1GND WIRE WRAP	13
2295893-1 TE Connectivity AMP Connectors	MALE INSERT HOUSING	0
09340032602 HARTING	INSERT MALE 3+2POS+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).