Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120062763 HARTING	INSERT FMALE 4+2POS+1GND PUSH IN	18
0936010219 Woodhead - Molex	6P + PE MALE INSERT 35A 830V/UL	40
1651350000 Weidmuller	INSERT MALE 10+2POS+1GND SCREW	253
0936010321 Woodhead - Molex	32P + PE MALE INSERT 16A 500V/UL	1
1-1103414-1 TE Connectivity AMP Connectors	INSERT MALE 10POS+1GND SCREW	0
09320123101 HARTING	INSERT FEMALE 12+2POS+1GND CRIMP	16
09140203113 HARTING	MODULE FEMALE 20POS CRIMP	103
09140022742 HARTING	MODULE FEMALE 2POS SCREW	142
1428990000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	3644
2-1103010-3 TE Connectivity AMP Connectors	INSERT MALE 25POS+1GND CRIMP	0
09210152601 HARTING	INSERT MALE 15POS+1GND WIRE WRAP	0
2-1104002-3 TE Connectivity AMP Connectors	INSERT FEMALE 8POS+1GND CRIMP	0
T2019092101-000 TE Connectivity AMP Connectors	HQ-008-M	75
11056483101 HARTING	MODULE FEMALE 48POS CRIMP	4
09140032702 HARTING	MODULE FEMALE 3POS SCREW	6
C146D10001E8 Tuchel / Amphenol	MODULE MALE 10POS CRIMP	209
T2111092201-000 TE Connectivity AMP Connectors	MODULE D-SUB FML 9POS HMN-009-F	0
1-1103640-9 TE Connectivity AMP Connectors	INSERT MALE 24POS+1GND SCREW	0
C14610B0101023 Tuchel / Amphenol	INSERT FEMALE 20+4POS+1GND SCREW	0
09120043051 HARTING	HAN Q4/0 -M- CRIMP	17

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).