Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
0936010536 Woodhead - Molex	S-M 16/6 M INS CRP 6P 16A 500V	0
5008121000 Woodhead - Molex	INSERT W/O CONTACTS MALE 10POS	1108
0936010245 Woodhead - Molex	4P X 80A + 8P X 16A + PE 500V/UL	5
0936010295 Woodhead - Molex	S-EP INSERT 24P MALE PUSH-IN TER	34
0936010544 Woodhead - Molex	S-M 16/8 M INS CRP 8P 16A 400V	0
0936010236 Woodhead - Molex	S-HSB 6P FEM 35A SCREW TERM	27
0936010085 Woodhead - Molex	108P + PE MALE INSERT 250V/UL600	0
0936010079 Woodhead - Molex	7P + PE MALE INSERT 10A 250V, UL	61
0936010436 Woodhead - Molex	S-Q5/0 230/400V 16A MALE 5 POLES	73
0936010543 Woodhead - Molex	S-M 16/8 F INS CRP 8P 16A 400V	0
0936010561 Woodhead - Molex	S-M 16/20 M INS CRP 20P 16A 400V	10
0936010231 Woodhead - Molex	10P + PE FEMALE INSERT 16A 500V/	0
0936010450 Woodhead - Molex	S-QD17 10A 250V 17P+PE MALE INSE	36
0936010554 Woodhead - Molex	S-M 10/12 F INS CRP 12P 10A 250V	0
0936010207 Woodhead - Molex	6P + PE FEMALE INSERT 16A 500V/U	58
0936010297 Woodhead - Molex	24P+PE FEMALE INSERT 16A 500V/UL	186
0936010091 Woodhead - Molex	15P + PE FEMALE INSERT 10A 250V/	8
0936010101 Woodhead - Molex	25P + PE MALE INSERT 10A 250V/UL	37
0936010265 Woodhead - Molex	16B SEST F INS SCRW 16P 16A 500V	47
0936010555 Woodhead - Molex	S-M 10/12 M INS CRP 12P 10A 250V	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).