Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010104 Woodhead - Molex	40P + PE MALE INSERT 10A 250V/UL	20
C14610B0031023 Tuchel / Amphenol	INSERT FEMALE 3+2POS+1GND SCREW	0
1014424 Phoenix Contact	CONN INSERT MALE 46POS	2297
09120123004 HARTING	INSERT HAN 12/0 MALE 1,5MM	18
1745800000 Weidmuller	INSERT FEMALE 16POS+1GND CLAMP	102
09150013123 HARTING	INSERT FEMALE 1POS CRIMP	0
09140082634 HARTING	MODULE MALE 8POS PUSH IN LOCK	0
HEE-032-M TE Connectivity AMP Connectors	INSERT MALE 32POS+1GND HEE-032-M	39
09700202622 HARTING	INSERT MALE 20POS SCREW	2
09330162791 HARTING	INSERT FEMALE 16POS SCREW	1
10196000 LAPP	CONN INSERT HBE24 MALE	103
09110013121 HARTING	MODULE FEMALE 1POS CRIMP	0
09155123002 HARTING	HAN F+B 4/4 HYBRID WITH ETHERNET	20
09120123101 HARTING	INSERT FEMALE 12P CRIMP PUSH IN	43
1584033 Phoenix Contact	INSERT MALE 24POS CRIMP	2486
1023350000 Weidmuller	INSERT FEMALE 8POS+1GND SCREW	0
C14610B0065001 Tuchel / Amphenol	INSERT FEMALE 6POS+1GND CRIMP	0
09160552001 HARTING	HAN 55DDD MALE CRIMP INSERT	14
09140022602 HARTING	MODULE MALE 2POS SCREW	4
44423229 LAPP	MODULE MH BUS PIN HOLDER M	20

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).