Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09161072101 HARTING	HAN 107DDD FEMALE CRIMP INSERT	25
1814300000 Weidmuller	MODULE BUS FEMALE 4POS SCREW	315
09330164636 HARTING	INSERT MALE 16P+1GND TERM BLOCK	4
HEEE-064-F 65-128 TE Connectivity AMP Connectors	INSRT 64P+1GND HEEE-064-F 65-128	43
09120043113 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
2-1103110-3 TE Connectivity AMP Connectors	INSERT MALE 40POS+1GND CRIMP	34
T2050322101-000 TE Connectivity AMP Connectors	HEE-032-M	8
1745790000 Weidmuller	INSERT FEMALE 24POS+1GND CLAMP	76
09140122632 HARTING	MODULE MALE 12POS PUSH IN LOCK	106
C14610B0068101 Tuchel / Amphenol	INSERT FEMALE 6POS+1GND SCREW	0
09120023151 HARTING	INSERT FEMALE 2POS+1GND CRIMP	3
09160723001 HARTING	INSERT MALE 72POS+1GND CRIMP	25
09330104639 HARTING	INSERT MALE 10P+1GND TERM BLOCK	0
T2113000201-000 TE Connectivity AMP Connectors	MOD RJ45 FEMALE 8POS HMN-RJ45-F	58
09330162648 HARTING	HAN 16 ES PRESS - M	0
1003200000 Weidmuller	INSERT FEMALE 17POS+1GND CRIMP	0
09120062611 HARTING	INSERT MALE 4+2POS+1GND CRIMP	9
09120022752 HARTING	INSERT FEMALE 2POS+1GND SCREW	0
09120052733 HARTING	INSERT FEMALE 5POS PUSH IN LOCK	53
09140023125 HARTING	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).