Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09110013021 HARTING	MODILE MALE 1POS CRIMP	0
09120012794 HARTING	INSERT WITH USB MALE 4POS CRIMP	1
09320183101 HARTING	INSERT FEMALE 18POS+1GND CRIMP	7
09330244725 HARTING	INSERT FMALE 24P+1GND TERM BLOCK	8
09320463111 HARTING	INSERT FEMALE 46POS+1GND CRIMP	13
09140032601 HARTING	MODULE MALE 3POS SCREW	288
09338162704 HARTING	HAN HIGH TEMP 16E CRIMP FEMALE	0
09120062701 HARTING	INSERT FEMALE 4+2POS+1GND CRIMP	0
11053253101 HARTING	MODULE FEMALE 25POS CRIMP	21
09801130400 HARTING	HAN-MODULAR SWITCH US4	0
09320463101 HARTING	INSERT FEMALE 46POS+1GND CRIMP	8
11051052823 HARTING	HAN-YELLOCK MULTIPLIER 2 AND 3 B	0
09380052621 HARTING	INSERT MALE 3POS SCREW	1
09310063001 HARTING	HAN 6HSB MALE CRIMP TERMINAL INS	15
09332062602 HARTING	HAN 6E HMC-M-CRIMP	23
09340062701 HARTING	INSERT FEMALE 6+2POS+1GND SCREW	16
09322643101 HARTING	HAN 64EEE HMC-F-CRIMP	0
09210403001 HARTING	INSERT MALE 40POS+1GND CRIMP	14
09330162602 HARTING	INSERT MALE 16POS+1GND CRIMP	1
09210643101 HARTING	INSERT FEMALE 64POS+1GND CRIMP	6

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).