Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140013172 HARTING	HAN PE-MODULE FEM. CRIMP 16QMM	0
T2060062201-000 TE Connectivity AMP Connectors	HSB-006-F	31
0936010535 Woodhead - Molex	S-M 16/6 F INS CRP 6P 16A 500V	0
C146 10A004 100 13 Tuchel / Amphenol	INSERT MALE 4POS SCREW	0
09160423101 HARTING	INSERT FEMALE 42POS+1GND CRIMP	8
1826770000 Weidmuller	INSERT MALE 46POS+1GND CRIMP	83
0936010448 Woodhead - Molex	3A SQ12/0 M INS CRP 12P 10A 400V	98
09120022655 HARTING	HAN Q 2/0-M 1.5QMM	13
0936010437 Woodhead - Molex	S-QD4/2 40A 400/690V 4P+PE 2P10A	18
T2030422101-000 TE Connectivity AMP Connectors	INSERT MALE 42POS+1GND HDD-042-M	20
T2080052201-000 TE Connectivity AMP Connectors	HQ-005-F	0
T2040244201-000 TE Connectivity AMP Connectors	INSERT FEMALE 24POS+GND CRIMP	28
0936010271 Woodhead - Molex	S-EP INSERT 16P FEM PUSH-IN TERM	30
09120062665 HARTING	HAN Q 4/2 MALE AXIAL SCREW INSER	0
C146 B01 004 E8 Tuchel / Amphenol	MODULE FEMALE 1POS CRIMP	0
09120022755 HARTING	HAN Q 2/0-F 1.5QMM	0
09365062601 HARTING	HAN 6E EX MALE SCREW TERMINAL IN	5
09380323101 HARTING	INSERT FEMALE 8+24POS+1GND CRIMP	2
0936010084 Woodhead - Molex	CRIMP TYPE INSERT MALE	0
1584046 Phoenix Contact	INSERT FEMALE 24POS CRIMP	131981

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).