Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
T2080122101-000 TE Connectivity AMP Connectors	HQ-012-M	26
C14610B0248101 Tuchel / Amphenol	INSERT FEMALE 24POS+1GND SCREW	0
1003160000 Weidmuller	INSERT FEMALE 6POS CRIMP	3918
1679414 Phoenix Contact	INSERT MALE 4POS SCREW	331
09200162816 HARTING	HAN 32A - 16A FEMALE SCREW TERMI	96
1584871 Phoenix Contact	INSERT MALE 16POS+1GND SCREW	540
09110012771 HARTING	MODULE FEMALE 1POS SCREW	0
09210642601 HARTING	INSERT MALE 64POS+1GND WIRE WRAP	1
09210644701 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	3
T2020072101-000 TE Connectivity AMP Connectors	INSERT MALE 7POS+1GND CRIMP	18
T2111202201-000 TE Connectivity AMP Connectors	MODULE FEMALE 20POS HMN-020-F	82
09330164626 HARTING	INSERT MALE 16P+1GND TERM BLOCK	4
09930010302 HARTING	HAN S BULKHEAD MOUNT HOUSING, RE	0
2-1103105-3 TE Connectivity AMP Connectors	INSERT FEMALE 8POS+1GND CRIMP	67
C14610B0160044 Tuchel / Amphenol	INSERT FEMALE 16POS+1GND SCREW	0
09140083116 HARTING	MODULE FEMALE 8POS (2X4) CRIMP	0
09140052701 HARTING	HAN E SCREW MODULE - FEMALE	51
09330064639 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	8
1584059 Phoenix Contact	INSERT MALE 42POS+1GND CRIMP	2331
09330062772 HARTING	INSERT FEMALE 6POS+1GND PUSH IN	1

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).