Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1119110000 Weidmuller	INSERT MALE 1POS CRIMP	0
1873590000 Weidmuller	INSERT MALE 24POS+1GND PUSH IN	68
1079780000 Weidmuller	INSERT MALE 1POS CRIMP	0
1157970000 Weidmuller	HDC CM ST M	2940
1789990000 Weidmuller	INSERT MALE 4POS+1GND SCREW	15
1730130000 Weidmuller	MODULE FEMALE 4POS TENSION CLAMP	5580
1650770000 Weidmuller	INSERT MALE 16POS+1GND SCREW	123
2592230000 Weidmuller	Module,Plug insert,EIA/TIA T568B	0
1220800000 Weidmuller	INSERT MALE 24POS+1GND SCREW	225
1429370000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	6043
1120600000 Weidmuller	INSERT FEMALE 1POS CRIMP	0
1023240000 Weidmuller	INSERT MALE 4+2POS+1GND SCREW	0
1790000000 Weidmuller	INSERT MALE 6+12POS+1GND SCREW	14
1912440000 Weidmuller	INSERT MALE 5POS+1GND CRIMP	1930
1428890000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	4042
1789980000 Weidmuller	INSERT FEMALE 4POS+1GND SCREW	6
1498700000 Weidmuller	INSERT MALE 6POS+1GND SCREW	6216
1983720000 Weidmuller	MODULE W/O CONTACTS FEMALE 2POS	4
1079830000 Weidmuller	INSERT FEMALE 1POS CRIMP	0
1650600000 Weidmuller	INSERT FEMALE 8POS+1GND CRIMP	7139

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).