Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010532 Woodhead - Molex	S-M CX/4 M CONN 4P+SHLD 10A	20
1730120000 Weidmuller	MODULE MALE 4POS TENSION CLAMP	6310
T2032162201-000 TE Connectivity AMP Connectors	INS 108P+1GND HDD-108-F 109-216	45
1498100000 Weidmuller	INSERT MALE 3POS+1GND SCREW	30494
C14610B0645002 Tuchel / Amphenol	INSERT FEMALE 64POS+1GND CRIMP	0
09338062604 HARTING	HAN HIGH TEMP 6E CRIMP MALE	0
09380062611 HARTING	INSERT MALE 4+0POS+1GND SCREW	60
09140062633 HARTING	MODULE MALE 6POS PUSH IN LOCK	12
HMN-020-M TE Connectivity AMP Connectors	MODULE MALE 20POS HMN-020-M	96
1648160 Phoenix Contact	HEAVYCON FEMALE INSERT 6POS	15
09140044711 HARTING	MODULE W/O CONTACTS FEMALE 4POS	8
C146 10A003 102 3 Tuchel / Amphenol	INSERT MALE 3+2POS+1GND SCREW	0
2-1104012-3 TE Connectivity AMP Connectors	INSERT MALE 35POS+1GND CRIMP	0
C14610B0161023 Tuchel / Amphenol	INSERT FEMALE 16+2POS+1GND SCREW	0
T2100042201-000 TE Connectivity AMP Connectors	HK4/0-004-F,WITH ONE SLOT SCREW	12
1745770000 Weidmuller	INSERT FEMALE 10POS+1GND CLAMP	21
1950280000 Weidmuller	MOD RJ45 MALE 8P8C+4PWR CRIMP	1616
C146H01044G8 Tuchel / Amphenol	MOD PNEUMATIC FEMALE 1POS CRIMP	0
HMN-006-PF TE Connectivity AMP Connectors	MODULE FEMALE 6POS HMN-006-PF	16
1414358 Phoenix Contact	MODULE MALE 3POS CRIMP	51247

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).