Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120022656 HARTING	HAN Q 2/0-M HV 1.5QMM	0
2-1103634-3 TE Connectivity AMP Connectors	INSERT MALE 6POS+1GND CRIMP	0
HMN-006-F TE Connectivity AMP Connectors	MODULE FEMALE 6POS HMN-006-F	191
1580538 Phoenix Contact	HC-K 6/0-ESTS	153
09210644702 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	0
C14610B0155002 Tuchel / Amphenol	INSERT FEMALE 15POS+1GND CRIMP	0
09330242772 HARTING	INSERT FEMALE 24POS+1GND PUSH IN	10
T2021282201-000 TE Connectivity AMP Connectors	INSERT FEMALE 64POS+1GND CRIMP	43
1648270 Phoenix Contact	INSERT MALE 16POS+1GND CRIMP	1
T2030722101-000 TE Connectivity AMP Connectors	INSERT MALE 72POS+1GND HDD-072-M	43
09142083111 HARTING	HAN GIGABIT HMC INSERT FEMALE	7
09338242604 HARTING	HAN HIGH TEMP 24E CRIMP MALE	0
C146 10A006 810 1 Tuchel / Amphenol	INSERT MALE 6POS+1GND SCREW	0
1983790000 Weidmuller	MOD W/O CONTACTS MALE 4POS CRIMP	0
C14610A0400602 Tuchel / Amphenol	INSERT MALE 40POS+1GND CRIMP	0
1651320000 Weidmuller	INSERT FEMALE 3+2POS+1GND SCREW	299
09210404702 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	2
T2111042101-000 TE Connectivity AMP Connectors	MODULE MALE 4POS HMN-004-M	99
09110012772 HARTING	MODULE FEMALE 1POS SCREW	1
09140012733 HARTING	HAN PE-MODULE FEM. AXIAL 16-35QM	10

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).