Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120062666 HARTING	INSERT MALE 4+2POS+1GND SCREW	10
09330162612 HARTING	INSERT MALE 16POS+1GND CRIMP	8
09338062603 HARTING	HAN HIGH TEMP 6E SCREW MALE	10
09330162788 HARTING	HAN 32ES - 16ES PRESS FEMALE INS	0
09340032616 HARTING	INSERT MALE 3+2POS+1GND PUSH IN	18
09210644611 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	2
09120042701 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
09332102648 HARTING	HAN 10E MALE ES PRESS INSERT, HI	14
09140023141 HARTING	MODULE FEMALE 2POS CRIMP	238
09330102691 HARTING	INSERT MALE 10POS+1GND SCREW	5
09150083013 HARTING	INSERT MALE 8POS CRIMP	103
09140012633 HARTING	HAN PE-MODULE MALE AXIAL 16-35QM	0
09200042634 HARTING	INSERT MALE 4POS+1GND PUSH IN	7
09161083101 HARTING	INSERT FEMALE 108POS+1GND CRIMP	102
09330242611 HARTING	INSERT MALE 24POS+1GND SCREW	6
09162243001 HARTING	HAN 24DD-HMC-M-C	1
09120042611 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	0
09330104629 HARTING	INSERT MALE 10P+1GND TERM BLOCK	7
09110012775 HARTING	MODULE FEMALE 1POS SCREW	1
09360082732 HARTING	INSERT FEMALE 8POS PUSH IN LOCK	16

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).