Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09210152601 HARTING	INSERT MALE 15POS+1GND WIRE WRAP	0
11056483101 HARTING	MODULE FEMALE 48POS CRIMP	4
09140032702 HARTING	MODULE FEMALE 3POS SCREW	6
09120043051 HARTING	HAN Q4/0 -M- CRIMP	17
09140033151 HARTING	HAN GUIDING RELAY MODULE (3PIN -	48
09210253001 HARTING	INSERT MALE 25POS+1GND CRIMP	99
09140012767 HARTING	MODULE FEMALE 1POS SCREW	6
09140063141 HARTING	MODULE FEMALE 6POS CRIMP	123
09120033013 HARTING	HAN BRID-RJ45 C-M RJ INDUPCRIAL	0
09140012762 HARTING	MODULE FEMALE 1POS SCREW	73
09120033011 HARTING	INSERT RJ45 MALE 8P8C IDC	4
09330164629 HARTING	INSERT MALE 16P+1GND TERM BLOCK	5
09120042711 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	28
09340062702 HARTING	INSERT FEMALE 6+2POS+1GND CRIMP	15
09330242691 HARTING	INSERT MALE 24POS SCREW	2
09340102716 HARTING	INSERT FEMALE 10+2P+1GND PUSH IN	0
09162243101 HARTING	HAN 24DD-HMC-F-C	1
09140063121 HARTING	HAN SHIELDED POWER MODULE, FEMAL	46
09120063001 HARTING	INSERT MALE 4+2POS+1GND CRIMP	13
09140123001 HARTING	MODULE MALE 12POS CRIMP	32

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).