Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120032774 HARTING	INSERT RJ45 FEMALE 8P8C IDC	6
1677034 Phoenix Contact	INSERT MALE 16POS CRIMP	0
09160723101 HARTING	INSERT FEMALE 72POS+1GND CRIMP	99
09200102614 HARTING	HAN 10A MALE SCREW TERMINAL INSE	27
1079790000 Weidmuller	INSERT MALE 1POS CRIMP	0
1424226 Phoenix Contact	CONN INSERT FEMALE 8POS	2544
2-1103008-3 TE Connectivity AMP Connectors	INSERT MALE 24POS+1GND CRIMP	0
09210404601 HARTING	INSERT MALE 46P+1GND TERM BLOCK	1
09140273113 HARTING	SHIELDED MODULE 27PIN FEMALE INS	8
09140064711 HARTING	HAN LC FEMALE MODULE FOR 6 LC CO	16
09322403001 HARTING	HAN 40EEE HMC-M-CRIMP	0
C146 A05 100 G8 Tuchel / Amphenol	MODULE MALE 4POS CRIMP	0
0936010289 Woodhead - Molex	24P+PE FEMALE INSERT 16A 500V/UL	19
T2111202101-000 TE Connectivity AMP Connectors	MODULE MALE 20POS HMN-020-M	88
1417372 Phoenix Contact	MODULE MALE 5POS TENSION CLAMP	111483
1014420 Phoenix Contact	CONN INSERT MALE 18POS	896
1023210000 Weidmuller	INSERT FEMALE 4+0POS+1GND SCREW	2645
09330244629 HARTING	INSERT MALE 24P+1GND TERM BLOCK	4
HMN-001-MC TE Connectivity AMP Connectors	MODULE MALE 1POS HMN-001-MC	58
1826790000 Weidmuller	INSERT MALE 32POS+1GND 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).