Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120013071 HARTING	INSERT FIREWIRE FMALE 6POS CRIMP	0
11051052804 HARTING	HAN YELLOCK MULTIPLIER 4:1	18
44423228 LAPP	MODULE MH BUS MODULE MALE	98
09210643001 HARTING	INSERT MALE 64POS+1GND CRIMP	7
C14610A0161021 Tuchel / Amphenol	INSERT MALE 16POS+1GND SCREW	1370
1828400000 Weidmuller	MODULE FEMALE 2POS SCREW	460
09380062601 HARTING	INSERT MALE 4+2POS+1GND SCREW	5
09120043111 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
C14610B0161021 Tuchel / Amphenol	INSERT FEMALE 16POS+1GND SCREW	2850
09380122751 HARTING	INSERT FEMALE 6+6POS+1GND SCREW	0
1207500000 Weidmuller	INSERT MALE 16POS+1GND SCREW	242
09340032716 HARTING	INSERT FMALE 3+2POS+1GND PUSH IN	9
1745840000 Weidmuller	INSERT MALE 16POS+1GND CLAMP	919
44423225 LAPP	MODULE MH-17 FEMALE CRIMP	94
C146B10001E8 Tuchel / Amphenol	MODULE FEMALE 10POS CRIMP	0
09930010101 HARTING	HAN S SCREW MOUNT HOUSING, BLACK	100
09322643001 HARTING	HAN 64EEE HMC-F-CRIMP	0
09380122701 HARTING	INSERT FEMALE 4+8POS+1GND SCREW	1
C14610A0061021 Tuchel / Amphenol	INSERT MALE 6POS+1GND SCREW	47
1855076 Phoenix Contact	INSERT W/O CONTACTS 50POS CRIMP	48

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).