Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09332102702 HARTING	HAN 10E HMC-F-CRIMP	20
09140083022 HARTING	HAN MEGABIT SINGLE ENTRY 2SHIELD	2
1584392 Phoenix Contact	INSERT MALE 25POS+1GND CRIMP	4
0936010262 Woodhead - Molex	S-EC INSERT 10P MALE CRIMP TERMI	0
09160283101 HARTING	HAN 28DD FEMALE CRIMP INSERT	10
1103020-2 TE Connectivity AMP Connectors	CONN STACKING INSERT	0
09140012634 HARTING	HAN PE-MODULE MALE AXIAL 38QMM	17
C146 10B004 100 13 Tuchel / Amphenol	INSERT FEMALE 4POS SCREW	0
09930010304 HARTING	HAN S BULKHEAD MOUNT HOUSING, RE	100
1584729 Phoenix Contact	INSERT FEMALE 18POS CRIMP	3709
09200162691 HARTING	HAN 16A MALE 8PAIR TYPE J THERMO	0
1079840000 Weidmuller	INSERT FEMALE 1POS CRIMP	0
09140014651 HARTING	MODULE USB MALE 4POS SCREW	23
C14610A00550012 Tuchel / Amphenol	INSERT MALE 5POS+1GND CRIMP	0
C14610A0100001 Tuchel / Amphenol	INSERT MALE 10POS+1GND CRIMP	0
0936010222 Woodhead - Molex	16A CRIMP MALE CONTACT 4MM GOLD	26
C14610A0645002 Tuchel / Amphenol	INSERT MALE 64POS+1GND CRIMP	0
T2019092201-000 TE Connectivity AMP Connectors	HQ-008-F	75
09140153001 HARTING	HAN 15E-M-C MULTIPLIERBLOCK	47
1498300000 Weidmuller	INSERT MALE 4POS+1GND SCREW	71204

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).