Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010103 Woodhead - Molex	40P + PE FEMALE INSERT 10A 250V/	46
0936010082 Woodhead - Molex	108P + PE FEMALE INSERT 250V/UL6	0
0936010093 Woodhead - Molex	24P + PE FEMALE INSERT 10A 250V/	3
0936010296 Woodhead - Molex	S-EC INS.16P MALE CRIMP TERM.17-	0
0936010273 Woodhead - Molex	16P + PE MALE INSERT 16A 500V/UL	105
0936010125 Woodhead - Molex	3P MALE INSERT 10A 250V, UL600V,	0
0936010204 Woodhead - Molex	S-EP INSERT 6P FEMALE PUSH-IN TE	23
0936010205 Woodhead - Molex	6P + PE MALE INSERT 16A 500V/UL	1
0936010244 Woodhead - Molex	10P + PE MALE INSERT 16A 500V/UL	18
0936010445 Woodhead - Molex	S-QD8/0 16A 500V SP+PE FEMALE IN	45
0936010548 Woodhead - Molex	S-M D/9 M D-SUB 9P 5A 50V	0
0936010329 Woodhead - Molex	46P+PE MALE INSERT 16A 500V/UL60	1
0936010238 Woodhead - Molex	10P + PE MALE INSERT 16A 500V/UL	1
0936010243 Woodhead - Molex	S-EC INSERT 6P FEM CRIMP TERMINA	17
0936010508 Woodhead - Molex	S-M 70/2 F INS CRP 2P 70A 1KV	0
0936010509 Woodhead - Molex	S-M 70/2 M INS CRP 2P 70A 1KV	0
0936010277 Woodhead - Molex	S-EP INSERT 16P MALE PUSH-IN TER	42
0936010299 Woodhead - Molex	24B SEST F INS SCRW 24P 16A 500V	16
0936010305 Woodhead - Molex	S-EP INSERT 24P FEM PUSH-IN TERM	17
0936010139 Woodhead - Molex	10P + PE MALE INSERT 16A 250V/UL	35

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).