Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09310062601 HARTING	INSERT MALE 6POS+1GND SCREW	50
09330244625 HARTING	INSERT MALE 24P+1GND TERM BLOCK	0
09200162813 HARTING	INSERT FEMALE 16POS+1GND SCREW	6
09451001100 HARTING	INSERT RJ45 MALE 6P4C IDC	38
09140052601 HARTING	HAN E SCREW MODULE - MALE	37
09120082733 HARTING	INSERT FEMALE 8POS PUSH IN LOCK	0
09800030200 HARTING	HAN-MODULAR SP SO DM2	10
09330164625 HARTING	INSERT MALE 16P+1GND TERM BLOCK	2
09140052716 HARTING	MODULE FEMALE 5POS PUSH IN	0
09200042633 HARTING	INSERT MALE 4POS+1GND PUSH IN	6
09330062672 HARTING	INSERT MALE 6POS+1GND PUSH IN	10
09120022611 HARTING	MODULE MALE 2POS CRIMP	0
09120022656 HARTING	HAN Q 2/0-M HV 1.5QMM	0
09210644702 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	0
09330242772 HARTING	INSERT FEMALE 24POS+1GND PUSH IN	10
09142083111 HARTING	HAN GIGABIT HMC INSERT FEMALE	7
09338242604 HARTING	HAN HIGH TEMP 24E CRIMP MALE	0
09210404702 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	2
09110012772 HARTING	MODULE FEMALE 1POS SCREW	1
09140012733 HARTING	HAN PE-MODULE FEM. AXIAL 16-35QM	10

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).