Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010203 Woodhead - Molex	6P + PE FEMALE INSERT 16A 500V/U	3
1102886-1 TE Connectivity AMP Connectors	INSERT MALE 46POS+1GND CRIMP	0
1648186 Phoenix Contact	INSERT FEMALE 10POS SCREW	31
1963840000 Weidmuller	CONN MOD JACK 8P8C SHIELDED	11
C14610B0040024 Tuchel / Amphenol	INSERT FEMALE 4POS+1GND SCREW	20
09380182602 HARTING	INSERT MALE 6+12POS+1GND SCREW	2
09380423001 HARTING	INSERT MALE 6+36POS+1GND CRIMP	1
09380052601 HARTING	INSERT MALE 3+2POS+1GND SCREW	9
09161083011 HARTING	INSERT MALE 108POS+1GND CRIMP	1
1424228 Phoenix Contact	CONN INSERT FEMALE 12POS	153
09360062602 HARTING	HAN 6EX INSERT MALE CRIMP	0
09140083001 HARTING	MODULE MALE 8POS CRIMP	426
09140013001 HARTING	MODULE MALE 1POS CRIMP	10
09120063041 HARTING	INSERT MALE 4+2POS+1GND CRIMP	160
T2040104101-000 TE Connectivity AMP Connectors	INSERT MALE 10POS+GND CRIMP	24
C14610B0245001 Tuchel / Amphenol	INSERT FEMALE 24POS+1GND CRIMP	0
HMN-025-F TE Connectivity AMP Connectors	MODULE FEMALE 25POS HMN-025-F	127
HE-024-M TE Connectivity AMP Connectors	INSERT MALE 24POS SCREW	12
09210072632 HARTING	INSERT MALE 7POS+1GND PUSH IN	0
1674736 Phoenix Contact	INSERT FEMALE 72POS 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).