Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09360082732 HARTING	INSERT FEMALE 8POS PUSH IN LOCK	16
10541000 LAPP	CONN INSERT HA10 17-32 FEMALE	34
09140083117 HARTING	MODULE FEMALE 8POS (2X4) CRIMP	9
09162723001 HARTING	HAN 72DD-HMC-M-C	6
09140093001 HARTING	MODULE MALE 9POS CRIMP	0
09340032701 HARTING	INSERT FEMALE 3+2POS+1GND SCREW	1
1772492 Phoenix Contact	INSERT FEMALE 40POS CRIMP	0
09451001560 HARTING	INSERT RJ45 MALE 8P8C IDC	5
1204100000 Weidmuller	INSERT FEMALE 10POS+1GND SCREW	18
T2080062201-100 TE Connectivity AMP Connectors	HQ4/2-F	10
09120043151 HARTING	HAN Q4/0 -F- CRIMP	0
T2110052201-000 TE Connectivity AMP Connectors	MODULE FEMALE 5POS HMN-005-FS	75
0511950800 Woodhead - Molex	INSERT W/O CONTACTS FEMALE 8POS	0
09120042603 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	30
09110013112 HARTING	HAN 1 HC-F-TC650	2
0936010092 Woodhead - Molex	15P + PE MALE INSERT 10A 250V/UL	5
0936010318 Woodhead - Molex	32P + PE FEMALE INSERT 16A 500V/	5
T2080122201-000 TE Connectivity AMP Connectors	HQ-012-F	26
09150043013 HARTING	INSERT MALE 4POS CRIMP	172
09140063001 HARTING	MODULE MALE 6POS CRIMP	740

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).