Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
HEEE-048-F TE Connectivity AMP Connectors	INSERT FML 48POS+1GND HEEE-048-F	56
09340162701 HARTING	INSERT FEMALE 16+2POS+1GND SCREW	2
19410102601 HARTING	HAN-ECO 10E-M-S	7
09110012755 HARTING	MODULE FEMALE 1POS SCREW	2
09380052722 HARTING	INSERT FEMALE 3POS SCREW	2
09120023101 HARTING	MODULE FEMALE 2POS CRIMP	0
1648335 Phoenix Contact	INSERT MALE 24POS+1GND CRIMP	18
C146 10B064 005 2 Tuchel / Amphenol	INSERT FEMALE 64POS+1GND CRIMP	0
09120042716 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
1417309 Phoenix Contact	MODULE D-SUB MALE 9POS CRIMP	45
09140022655 HARTING	MODULE MALE HAN 100A SCREW	3
09210644601 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	1
09360062701 HARTING	HAN 6EX-F-S	0
1079820000 Weidmuller	INSERT FEMALE 1POS CRIMP	0
1414363 Phoenix Contact	MODULE FEMALE 4POS CRIMP	7
09140022601 HARTING	MODULE MALE 2POS SCREW	186
09160752101 HARTING	HAN 75DDD FEMALE CRIMP INSERT	24
09200162612 HARTING	INSERT MALE 16POS+1GND SCREW	65
09365062602 HARTING	HAN 6E EX MALE CRIMP INSERT UL V	8
09380052701 HARTING	INSERT FEMALE 3+2POS+1GND SCREW	2

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).