Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140083121 HARTING	HAN MEGABIT SINGLE ENTRY CONTACT	0
1679456 Phoenix Contact	INSERT MALE 7POS+1GND CRIMP	0
T2021282101-000 TE Connectivity AMP Connectors	INSERT MALE 64POS+1GND CRIMP	43
10171000 LAPP	CONN INSERT HBS6 FEMALE	23
0936010529 Woodhead - Molex	S-M 40/4 F INS CRP 4P 40A 830V	0
09140044701 HARTING	MODULE W/O CONTACTS MALE 4POS	19
0936010565 Woodhead - Molex	S-M D/25M INS CRP 25P 4A 50V	0
09140013032 HARTING	INSERT MALE 1POS CRIMP SCREW	28
10420000 LAPP	CONN INSERT HA3 MALE	262
1043130000 Weidmuller	MODULE BUS MALE 8POS CRIMP	0
T2580032154-000 TE Connectivity AMP Connectors	T2580032154-000	38
0936010549 Woodhead - Molex	S-M D/9 F INS W/O D-SUB	0
09140032701 HARTING	MODULE FEMALE 3POS SCREW	317
C14610B0241021 Tuchel / Amphenol	INSERT FEMALE 24POS+1GND SCREW	22
11/2408 LAPP	CONN INSERT PWRK 4+8 MALE	6
HMN-008-M TE Connectivity AMP Connectors	MODULE MALE 8POS HMN-008-M	119
09330104725 HARTING	INSERT FMALE 10P+1GND TERM BLOCK	7
C14610B0420009 Tuchel / Amphenol	INSERT FEMALE 42POS+1GND CRIMP	0
11051053001 HARTING	MODULE MALE 5POS CRIMP	41
09330242791 HARTING	INSERT FEMALE 24POS SCREW	2

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).