Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1407736 Phoenix Contact	HC-B 24-I-PT-M	1035
09150013004 HARTING	HAN COAX ETCS MODULE MALE	38
09140033501 HARTING	HAN PNEUMATIC MODULE METAL M	133
09140123101 HARTING	MODULE FEMALE 12POS CRIMP	309
1861920000 Weidmuller	MODULE MALE 4POS CRIMP	6290
09330244639 HARTING	INSERT MALE 24P+1GND TERM BLOCK	4
09120123002 HARTING	INSERT MALE 12POS SOLDER	0
09330102772 HARTING	INSERT FEMALE 10POS+1GND PUSH IN	1
0936010112 Woodhead - Molex	64P + PE MALE INSERT 250V/UL600V	10
C14610B0240001 Tuchel / Amphenol	INSERT FEMALE 24POS+1GND CRIMP	0
09120062695 HARTING	INSERT MALE 4+2POS+1GND PUSH IN	10
09110012652 HARTING	MODULE MALE 1POS SCREW	5
09140033051 HARTING	HAN GUIDING RELAY MODULE (3PIN -	36
44423213 LAPP	MODULE MH-2 FEMALE CRIMP	40
09120033016 HARTING	HAN-BRID RJ45C-M-RJ INDUSTRIAL C	0
1651170000 Weidmuller	INSERT MALE 42POS+1GND CRIMP	47110
1601730000 Weidmuller	INSERT FEMALE 40POS+1GND CRIMP	0
09330104625 HARTING	INSERT MALE 10P+1GND TERM BLOCK	2
09140023102 HARTING	MODULE FEMALE 2POS CRIMP	143
09160283001 HARTING	HAN 28DD MALE CRIMP INSERT	5

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).