Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1120590000 Weidmuller	INSERT MALE 1POS CRIMP	0
1983750000 Weidmuller	MODULE W/O CONTACTS MALE 2POS	0
1043120000 Weidmuller	MODULE BUS FEMALE 8POS CRIMP	0
1601720000 Weidmuller	INSERT MALE 64POS+1GND CRIMP	2129
1428930000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	1625
1650650000 Weidmuller	INSERT MALE 15POS+1GND CRIMP	3350
2592210000 Weidmuller	Module,Pluginsert, RJ45tool-free	6
1023360000 Weidmuller	INSERT MALE 8POS+1GND SCREW	412
1873520000 Weidmuller	INSERT FEMALE 6POS+1GND PUSH IN	2345
1650900000 Weidmuller	INSERT FEMALE 16POS+1GND SCREW	4872
1651360000 Weidmuller	INSERT FEMALE 10+2POS+1GND SCREW	63
1157980000 Weidmuller	HDC CM ST F	939
1429080000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	1450
1023290000 Weidmuller	HDC S8/24 MC	0
1651300000 Weidmuller	INSERT FEMALE 108POS+1GND CRIMP	0
1894760000 Weidmuller	MODULE PNEUMATIC FEMALE 2POS	2
1806030000 Weidmuller	MODULE BUS FEMALE 2POS SCREW	0
1023340000 Weidmuller	HDC S12/2 MC	0
913540 Weidmuller	INSERT FEMALE 16POS CRIMP	0
913280 Weidmuller	INSERT FEMALE 24POS CRIMP	0

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).