Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010284 Woodhead - Molex	18P + PE MALE INSERT 16A 500V/UL	7
0936010111 Woodhead - Molex	64P + PE FEMALE INSERT 250V/UL60	0
0936010515 Woodhead - Molex	S-M 40/2C M INS CRP 2P 40A 1KV	0
0936010121 Woodhead - Molex	3P FEMALE INSERT 10A 250V, UL600	0
0936010099 Woodhead - Molex	25P + PE FEMALE INSERT 10A 250V/	27
0936010263 Woodhead - Molex	16P + PE FEMALE INSERT 16A 500V/	40
0936010135 Woodhead - Molex	3A SA M INS SCRWAU 4P 10A 250/40	50
0936010259 Woodhead - Molex	16P + PE MALE INSERT 16A 500V/UL	3
0936010446 Woodhead - Molex	S-QD8/0 16A 500V SP+PE MALE INSE	0
0936010206 Woodhead - Molex	S-EP INSERT 6P MALE PUSH-IN TERM	18
0936010198 Woodhead - Molex	MALE INSERT 4X80A	9
0936010267 Woodhead - Molex	S-ES INSERT 16P FEM SPRING TERM	43
0936010113 Woodhead - Molex	72P + PE FEMALE INSERT 10A 250V/	10
0936010534 Woodhead - Molex	S-M 16/5 M INS SPRING 5P 16A 400	0
0936010547 Woodhead - Molex	S-M D/9 F D-SUB CRP 9P 5A 50V	0
0936010197 Woodhead - Molex	FEMALE INSERT 4X80A	22
0936010435 Woodhead - Molex	S-Q5/0 230/400V 16A FEMALE 5 POL	0
0512031200 Woodhead - Molex	INSERT W/OUT CONTACTS MALE 12POS	330400
0936010142 Woodhead - Molex	CRIMP TYPE INSERT MALE	17
0936010301 Woodhead - Molex	S-ES INSERT 24P FEM SPRING TERM	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).