Heavy Duty Connectors - Inserts, Modules

Image Part Number Description / PDF Quantity Rfq
0936010506

0936010506

Woodhead - Molex

S-M 100/2 F INS CRP 2P 100A 1KV

0

0936010291

0936010291

Woodhead - Molex

S-EP INSERT 24P FEMALE PUSH-IN T

11

0936010513

0936010513

Woodhead - Molex

S-M 40/2A M INS SCRAX 2X40A 1KV

0

0936010311

0936010311

Woodhead - Molex

S-EP INSERT 24P MALE PUSH-IN TER

0

0936010221

0936010221

Woodhead - Molex

MALE INSERT 4X80A + 2X16A

6

0936010256

0936010256

Woodhead - Molex

S-HSB 6P MALE 35A SCREW TERM

0

0936010106

0936010106

Woodhead - Molex

42P + PE MALE INSERT 10A 250V/UL

13

0936010114

0936010114

Woodhead - Molex

S-DD INSERT 72P FEM

10

0936010137

0936010137

Woodhead - Molex

10P + PE FEMALE INSERT 16A 250V/

16

0936010447

0936010447

Woodhead - Molex

3A SQ12/0 F INS CRP 12P 10A 400V

96

0936010227

0936010227

Woodhead - Molex

10P + PE FEMALE INSERT 16A 500V/

9

0936010526

0936010526

Woodhead - Molex

S-M 40/3C M INS CRP 3P 40A 500V

0

0936010257

0936010257

Woodhead - Molex

S-EP INSERT 16P FEMALE PUSH-IN T

16

0936010449

0936010449

Woodhead - Molex

S-QD17 10A 250V 17P+PE FEMALE IN

32

0936010309

0936010309

Woodhead - Molex

24B SEST M INS SCRW 24P 16A 500V

13

0936010507

0936010507

Woodhead - Molex

S-M 100/2 M INS CRP 2P 100A 1KV

0

0936014741

0936014741

Woodhead - Molex

RJ45 PLUG 8P4C P/NET+MET. HE HOO

0

0936010274

0936010274

Woodhead - Molex

16B SE M INS SCRWAG 16P 16A 500V

0

0936010117

0936010117

Woodhead - Molex

S-DD 72P SILVER FEM INSERT PCB A

0

0936014796

0936014796

Woodhead - Molex

RJ45 PLUG 8P8C+MET. STD HOOD +PG

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

TypeFunctional FeaturesApplication Examples
Modular Insert SystemsCustomizable contact arrangements, hot-swappable designIndustrial control cabinets, automated machinery
High-Power ModulesRated for >100A currents, integrated cooling channelsElectric vehicle charging stations, factory automation
Signal Transmission InsertsShielded contacts for <10Gbps data ratesSmart grid monitoring systems, robotics
Hybrid Power-Signal ModulesCombined power and fiber optic transmissionWind 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

ParameterImportance
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

ManufacturerRepresentative Product
TE ConnectivityDEUTSCH HC Series High-Current Connectors
Amphenol IndustrialMAXdur Hybrid Power/Sig nal Modules
Phoenix ContactHeavycon Modular Insert Systems
Weidm llerHA-Modular Hybrid Connection Technology

7. Selection Guidelines

Key considerations:

  1. Calculate maximum current/voltage requirements with safety margins
  2. Assess environmental factors (temperature, vibration, chemicals)
  3. Verify IP rating for ingress protection
  4. Evaluate mating cycle requirements
  5. Check industry-specific certifications (UL, CSA, IEC standards)
  6. 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).

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