Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
2592250000 Weidmuller	HDC MRJ45 8PLUG MC	4
1003160000 Weidmuller	INSERT FEMALE 6POS CRIMP	3918
1963830000 Weidmuller	CONN MOD JACK 8P8C SHIELDED	12
1650570000 Weidmuller	INSERT MALE 7POS+1GND CRIMP	10319
1873560000 Weidmuller	INSERT FEMALE 16POS+1GND PUSH IN	186
1200000000 Weidmuller	INSERT MALE 6POS+1GND SCREW	102171
1429020000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	3348
1896830000 Weidmuller	INSERT MALE 16POS+1GND PUSH IN	71
1003210000 Weidmuller	INSERT MALE 17POS+1GND CRIMP	0
1428880000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	39
1758380000 Weidmuller	MODULE MALE 5POS CRIMP	375330
1505650000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	4838
1682130000 Weidmuller	MODULE FEMALE 10POS CRIMP	345210
1861900000 Weidmuller	MODULE FEMALE 4POS CRIMP	11090
1983790000 Weidmuller	MOD W/O CONTACTS MALE 4POS CRIMP	0
1651320000 Weidmuller	INSERT FEMALE 3+2POS+1GND SCREW	299
1814300000 Weidmuller	MODULE BUS FEMALE 4POS SCREW	315
1745790000 Weidmuller	INSERT FEMALE 24POS+1GND CLAMP	76
1003200000 Weidmuller	INSERT FEMALE 17POS+1GND CRIMP	0
1650620000 Weidmuller	INSERT FEMALE 10POS+1GND SCREW	21

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).