Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010550 Woodhead - Molex	S-M D/9 M INS W/O D-SUB	0
0936010094 Woodhead - Molex	24P + PE MALE INSERT 10A 250V/UL	9
0936010214 Woodhead - Molex	16A CRIMP MALE CONTACT 2,5MM GO	25
0511940800 Woodhead - Molex	INSERT W/OUT CONTACTS MALE 8POS	765
0936010293 Woodhead - Molex	24P+PE MALE INSERT 16A 500V/UL60	0
0936010213 Woodhead - Molex	FEMALE INSERT 4X80A + 2X16A	7
0936010129 Woodhead - Molex	4P FEMALE INSERT 10A 250V, UL600	0
0936010067 Woodhead - Molex	S-DD/PCB 10A SILVER 6P ADAPTX1 6	0
0936010203 Woodhead - Molex	6P + PE FEMALE INSERT 16A 500V/U	3
0936010112 Woodhead - Molex	64P + PE MALE INSERT 250V/UL600V	10
0936010145 Woodhead - Molex	16P + PE FEMALE INSERT 16A 250V/	9
0936010261 Woodhead - Molex	S-EP INSERT 16P MALE PUSH-IN TER	15
0936010219 Woodhead - Molex	6P + PE MALE INSERT 35A 830V/UL	40
0936010321 Woodhead - Molex	32P + PE MALE INSERT 16A 500V/UL	1
0936010147 Woodhead - Molex	16P + PE MALE INSERT 16A 250V/UL	0
0936010559 Woodhead - Molex	S-M 10/17 M INS CRP 17P 10A 250V	140
0936010215 Woodhead - Molex	6P + PE MALE INSERT 16A 500V/UL	0
5008131000 Woodhead - Molex	CONN SOCKET HSG 10CKT	0
0936010531 Woodhead - Molex	S-M CX/4 F CONN 4P+SHLD 10A	20
0936010535 Woodhead - Molex	S-M 16/6 F INS CRP 6P 16A 500V	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).