Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09360083001 HARTING	INSERT MALE 8POS CRIMP	60
09700202816 HARTING	INSERT FEMALE 20POS SOLDER	5
T2111082101-000 TE Connectivity AMP Connectors	MODULE MALE 8POS HMN-008-M	79
1584444 Phoenix Contact	INSERT FEMALE 64POS+1GND CRIMP	13100
10432000 LAPP	CONN INSERT HA4 FEMALE	487
09210153001 HARTING	INSERT MALE 15POS+1GND CRIMP	95
09330102616 HARTING	INSERT MALE 10POS+1GND PUSH IN	10
09330104726 HARTING	INSERT FMALE 10P+1GND TERM BLOCK	0
T2050802101-000 TE Connectivity AMP Connectors	INS ML 40P+1GND HEEE-040-M 41-80	60
1417303 Phoenix Contact	MODULE FEMALE 8POS CRIMP	48
09330064635 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
C14610A00750012 Tuchel / Amphenol	INSERT MALE 7POS+1GND CRIMP	0
09140022647 HARTING	MODULE MALE 2POS SCREW	11
10193000 LAPP	CONN INSERT HBE10 FEMALE	78
1407731 Phoenix Contact	HC-B 16-I-PT-F	50108
C146 10B006 400 1 Tuchel / Amphenol	INSERT FEMALE 6POS+1GND SCREW	0
19410202701 HARTING	HAN ECO 20E-M-S	15
C14610B00610013 Tuchel / Amphenol	INSERT FEMALE 4+2POS+1GND SCREW	0
09330244735 HARTING	INSERT FMALE 24P+1GND TERM BLOCK	1
0936010077 Woodhead - Molex	7P + PE FEMALE INSERT 10A 250V,	109

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).