Heavy Duty Connectors - Inserts, Modules

Image	Part Number	Description / PDF	Quantity	Rfq
	0936010210 Woodhead - Molex	6B SEST F INS SCRW 6P 16A 500V O	0
	0936014755 Woodhead - Molex	RJ45 PLUG 8P4C P/NET+INS.HOOD BL	0
	0936014811 Woodhead - Molex	RJ45 PLUG 8P8C+2PC+INS.HOOD BLK	0
	0936010541 Woodhead - Molex	S-M 40/3/4 F INS CRP 3X40A+4X10A	0
	0936010310 Woodhead - Molex	24B SEST M INS SCRW 24P 16A 500V	0
	0936010440 Woodhead - Molex	3A SQ7PCB F INS AU 7X7.5A 250V F	0
	0936010393 Woodhead - Molex	24B SEHV M INS SCRW 10+2/16A 830	0
	0936010359 Woodhead - Molex	10B SESHV M INS SPRING 3P+2P 16A	0
	0936010278 Woodhead - Molex	16B SE M INS SCRW 32P 16A 500V N	0
	0936010524 Woodhead - Molex	S-M 40/3A M INS SCRAX 3X40A 690V	0
	0936010254 Woodhead - Molex	16B S-E/PCB M INS AU 16P 16A 500	0
	0936010330 Woodhead - Molex	S-EC INS.24P MALE CRIMP TERM.25-	0
	0936010068 Woodhead - Molex	S-DD/PCB 10A GOLD 6P ADAPT X 1 6	0
	0936010377 Woodhead - Molex	16B SEHV M INS SCRW 6+2/16A 830V	0
	0936010320 Woodhead - Molex	10B SK8/24 M INS CRP 8X16A+24X10	0
	0936010511 Woodhead - Molex	S-M 40/2A F INS SCRAX 2X40A 1KV	0
	0936010519 Woodhead - Molex	S-M CX2 M INS WXO CONNECTOR	0
	0936010086 Woodhead - Molex	S-DD INSERT 108P MALE	0
	0936010399 Woodhead - Molex	24B SEHV F INS SCRW 10+2/16A 830	0
	0936010442 Woodhead - Molex	3A SQ7PCB M INS AU 7X7.5A 250V F	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).