Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
HE-024-FS (25-48) TE Connectivity AMP Connectors	INSERT FEMALE 24POS CLAMP	11
1102896-1 TE Connectivity AMP Connectors	INSERT FEMALE 32POS+1GND CRIMP	0
C14610A0420009 Tuchel / Amphenol	INSERT MALE 42POS+1GND CRIMP	0
C14610B0160024 Tuchel / Amphenol	INSERT FEMALE 16POS+1GND SCREW	38
1580150 Phoenix Contact	INSERT MALE 40POS TERMINAL BLOCK	0
09700202621 HARTING	INSERT MALE 20POS SOLDER	4
1407745 Phoenix Contact	INSRT FEMAL 10+2POS+1GND PUSH-IN	0
09210252701 HARTING	INSERT FEMALE 25P+1GND WIRE WRAP	6
09120053104 HARTING	HAN Q 5/0 FEMALE CRIMP INSERT (1	157
0936010558 Woodhead - Molex	S-M 10/17 F INS CRP 17P 10A 250V	94
09161083001 HARTING	INSERT MALE 108POS+1GND CRIMP	0
1854019 Phoenix Contact	INSERT MALE 6POS SCREW	35
1586264 Phoenix Contact	INSERT FEMALE 2POS+1GND SCREW	51432
0936010438 Woodhead - Molex	S-QD4/2 40A 400/690V 4P+PE 2P10A	46
1679508 Phoenix Contact	INSERT FEMALE 7POS+1GND CRIMP	0
09140012632 HARTING	HAN PE-MODULE MALE AXIAL 10-25QM	0
HE-006-FS TE Connectivity AMP Connectors	INSERT FEMALE 6POS CLAMP	40
09140013102 HARTING	HAN 1MOD-F-C 200A FINGER PROTECT	60
1758390000 Weidmuller	MODULE FEMALE 5POS CRIMP	309130
1650780000 Weidmuller	INSERT FEMALE 16POS+1GND SCREW	1095

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).