Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1896830000 Weidmuller	INSERT MALE 16POS+1GND PUSH IN	71
09140022641 HARTING	MODULE MALE 2POS SCREW	207
09330064725 HARTING	INSERT FEMALE 6P+1GND TERM BLOCK	55
T2020802101-000 TE Connectivity AMP Connectors	INSERT MALE 40POS+1GND CRIMP	60
1014421 Phoenix Contact	CONN INSERT FEMALE 32POS	2437
1103277-1 TE Connectivity AMP Connectors	MODULE MALE 12POS CRIMP	0
1003210000 Weidmuller	INSERT MALE 17POS+1GND CRIMP	0
09380363101 HARTING	HAN K 9/9/18 FEMALE CRIMP INSERT	8
C146H02034G8 Tuchel / Amphenol	MOD PNEUMATIC FEMALE 2POS CRIMP	0
2-1103012-3 TE Connectivity AMP Connectors	INSERT MALE 40POS+1GND CRIMP	0
0936010277 Woodhead - Molex	S-EP INSERT 16P MALE PUSH-IN TER	42
09320463001 HARTING	INSERT MALE 46POS+1GND CRIMP	16
C146 10B040 500 2 Tuchel / Amphenol	INSERT FEMALE 40POS+1GND CRIMP	0
09140093101 HARTING	MODULE FEMALE 9POS CRIMP	237
09330104736 HARTING	INSERT FMALE 10P+1GND TERM BLOCK	0
C14610A0165001 Tuchel / Amphenol	INSERT MALE 16POS+1GND CRIMP	0
09142083116 HARTING	HAN MEGABIT HMC INSERT FEMALE	12
09700062615 HARTING	INSERT MALE 6POS SOLDER	49
09110013021 HARTING	MODILE MALE 1POS CRIMP	0
C146 B02 001 E8 Tuchel / Amphenol	MODULE FEMALE 2POS 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).