Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140012668 HARTING	MODULE MALE 1POS SCREW	3
09140012661 HARTING	MODULE MALE 95MM AXIAL	0
09140363101 HARTING	HAN HIGH DENSITY 36PIN MODULE FE	133
09142203013 HARTING	SHIELDED MODULE 20PIN MALE INSER	0
09930010501 HARTING	HAN S HOOD, ANGLED, BLACK, 25-50	200
09140022702 HARTING	MODULE FEMALE 2POS SCREW	3
09330242612 HARTING	INSERT MALE 24POS+1GND CRIMP	1
09150013023 HARTING	INSERT MALE 1POS CRIMP	1
09360083001 HARTING	INSERT MALE 8POS CRIMP	60
09700202816 HARTING	INSERT FEMALE 20POS SOLDER	5
09210153001 HARTING	INSERT MALE 15POS+1GND CRIMP	95
09330102616 HARTING	INSERT MALE 10POS+1GND PUSH IN	10
09330104726 HARTING	INSERT FMALE 10P+1GND TERM BLOCK	0
09330064635 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
09140022647 HARTING	MODULE MALE 2POS SCREW	11
19410202701 HARTING	HAN ECO 20E-M-S	15
09330244735 HARTING	INSERT FMALE 24P+1GND TERM BLOCK	1
09120032774 HARTING	INSERT RJ45 FEMALE 8P8C IDC	6
09160723101 HARTING	INSERT FEMALE 72POS+1GND CRIMP	99
09200102614 HARTING	HAN 10A MALE SCREW TERMINAL INSE	27

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).