Heavy Duty Connectors - Inserts, Modules

Image	Part Number	Description / PDF	Quantity	Rfq
	0936010253 Woodhead - Molex	16B S-E/PCB M INS AG 16P 16A 500	0
	0936010292 Woodhead - Molex	S-E INSERT 16P MALE SCREW TERMIN	0
	0936010294 Woodhead - Molex	S-EC INSERT 16P MALE CRIMP TERMI	0
	0936010371 Woodhead - Molex	16B SEHV F INS SCRW 6+2/16A 830V	0
	0544785215 Woodhead - Molex	INSERT MALE 52POS CRIMP	0
	0936010365 Woodhead - Molex	10B SEHV M INS CRP 3+2/16A 830V	0
	0936010218 Woodhead - Molex	6B SEST M INS SCRW 6P 16A 500V O	0
	0936010146 Woodhead - Molex	16A SA F INS SCRW 16P 16A 250V N	0
	0936060004 Woodhead - Molex	POWER INTERFACES	0
	0936010332 Woodhead - Molex	24B SEEE M INS CRP 64P 16A 500V	0
	0936010378 Woodhead - Molex	16B SEHV M INS SCRW 6+2/16A 830V	0
	0936010533 Woodhead - Molex	S-M 16/5 F INS SPRING 5P 16A 400	0
	0936010427 Woodhead - Molex	3A SQ2/0 F INS SCRAX 2P 40A 400V	0
	0936010302 Woodhead - Molex	24B SE F INS SCRW 24P 16A 500V N	0
	0936010154 Woodhead - Molex	CRIMP TYPE INSERT MALE	0
	0936010328 Woodhead - Molex	S-EC INSERT 24P MALE CRIMP TERMI	0
	0936060005 Woodhead - Molex	POWER INTERFACES	0
	0936010306 Woodhead - Molex	S-ES INSERT 24P MALE SPRING TERM	0
	0936014747 Woodhead - Molex	RJ45 PLUG 8P4C+INS.HOOD BLK +M20	0
	0936014823 Woodhead - Molex	RJ45 PLUG 8P8C+2PC+INS.HOOD BLK	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).