Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010213 Woodhead - Molex	FEMALE INSERT 4X80A + 2X16A	7
09140124501 HARTING	MODULE MALE 12POS CRIMP	0
1650810000 Weidmuller	INSERT MALE 25POS+1GND CRIMP	1
09120042606 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	0
C14610A0160001 Tuchel / Amphenol	INSERT MALE 16POS+1GND CRIMP	0
09161083111 HARTING	INSERT FEMALE 108POS+1GND CRIMP	5
09140083016 HARTING	MODULE MALE 8POS (2X4) CRIMP	179
C146 10B017 500 12 Tuchel / Amphenol	INSERT FEMALE 17POS+1GND CRIMP	0
0936010129 Woodhead - Molex	4P FEMALE INSERT 10A 250V, UL600	0
09140082733 HARTING	MODULE FEMALE 8POS PUSH IN LOCK	50
09330102702 HARTING	INSERT FEMALE 10POS+1GND CRIMP	15
1790020000 Weidmuller	INSERT FEMALE 6+6POS+1GND SCREW	36
2-1103635-3 TE Connectivity AMP Connectors	INSERT FEMALE 6POS+1GND CRIMP	1
0936010067 Woodhead - Molex	S-DD/PCB 10A SILVER 6P ADAPTX1 6	0
09140052647 HARTING	MODULE MALE 5POS CRIMP/SCREW	0
HMN-006-M TE Connectivity AMP Connectors	MODULE MALE 6POS HMN-006-M	191
1772874 Phoenix Contact	INSERT MALE 24POS TERMINAL BLOCK	0
09330242748 HARTING	HAN 24 ES PRESS - F	13
1648296 Phoenix Contact	INSERT MALE 24POS SCREW	72
C14610B0100021 Tuchel / Amphenol	INSERT FEMALE 10POS+1GND SCREW	22

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).