Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010115 Woodhead - Molex	72P + PE MALE INSERT 10A 250V/UL	10
0936010530 Woodhead - Molex	S-M 40/4 M INS CRP 4P 40A 830V	0
0936010081 Woodhead - Molex	CRIMP TYPE INSERT FEMALE	0
0511950800 Woodhead - Molex	INSERT W/O CONTACTS FEMALE 8POS	0
0936010092 Woodhead - Molex	15P + PE MALE INSERT 10A 250V/UL	5
0936010318 Woodhead - Molex	32P + PE FEMALE INSERT 16A 500V/	5
0936010307 Woodhead - Molex	24P+PE MALE INSERT 16A 500V/UL60	389
0936010143 Woodhead - Molex	16P + PE FEMALE INSERT 16A 250V/	0
0936010327 Woodhead - Molex	46P+PE FEMALE INSERT 16A 500V/UL	0
0936010255 Woodhead - Molex	16P + PE FEMALE INSERT 16A 500V/	23
0936010529 Woodhead - Molex	S-M 40/4 F INS CRP 4P 40A 830V	0
0936010565 Woodhead - Molex	S-M D/25M INS CRP 25P 4A 50V	0
0936010549 Woodhead - Molex	S-M D/9 F INS W/O D-SUB	0
0936010237 Woodhead - Molex	10P + PE FEMALE INSERT 16A 500V/	8
0936010283 Woodhead - Molex	18P + PE FEMALE INSERT 16A 500V/	7
0936010149 Woodhead - Molex	16P + PE MALE INSERT 16A 250V/UL	10
0936010275 Woodhead - Molex	16B SEST M INS SCRW 16P 16A 500V	47
0936010512 Woodhead - Molex	S-M 40/2A M INS SCRAX 2X40A 1KV	0
0512041200 Woodhead - Molex	INSERT W/O CONTACTS FEMALE 12POS	290
0936010133 Woodhead - Molex	4P MALE INSERT 10A 250V, UL600V,	88

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).