Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09700062812 HARTING	INSERT FEMALE 6POS SOLDER	9
C14610A0060021 Tuchel / Amphenol	INSERT MALE 6POS+1GND SCREW	0
09160403101 HARTING	HAN 40DD FEMALE CRIMP INSERT	25
1828410000 Weidmuller	MODULE FEMALE 2POS SCREW	75
1873570000 Weidmuller	INSERT MALE 16POS+1GND PUSH IN	813
09365162702 HARTING	HAN 16E EX FEMALE CRIMP INSERT U	9
09120023052 HARTING	INSERT MALE 2POS+1GND CRIMP	17
09340102616 HARTING	INSERT MALE 10+2POS+1GND PUSH IN	0
1584334 Phoenix Contact	INSERT MALE 7POS+1GND CRIMP	3030
1679333 Phoenix Contact	INSERT MALE 4+8POS+1GND SCREW	1
T2031442101-000 TE Connectivity AMP Connectors	INS ML 72P+1GND HDD-072-M 73-144	43
C146 A03 501 E8 Tuchel / Amphenol	MODULE MALE 3POS CRIMP	0
C14610A0245001 Tuchel / Amphenol	INSERT MALE 24POS+1GND CRIMP	0
C14610A0161024 Tuchel / Amphenol	INSERT MALE 16POS+1GND SCREW	0
09140083101 HARTING	MODULE FEMALE 8POS CRIMP	629
C146 10B012 100 13 Tuchel / Amphenol	INSERT FEMALE 4+8POS+1GND SCREW	0
1-1103635-1 TE Connectivity AMP Connectors	INSERT FEMALE 6POS+1GND SCREW	0
T2111252201-000 TE Connectivity AMP Connectors	MODULE FEMALE 25POS HMN-025-F	34
09330242616 HARTING	INSERT MALE 24POS+1GND PUSH IN	0
44423212 LAPP	MODULE MH-2 MALE CRIMP	40

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).