Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09160283101 HARTING	HAN 28DD FEMALE CRIMP INSERT	10
09140012634 HARTING	HAN PE-MODULE MALE AXIAL 38QMM	17
09930010304 HARTING	HAN S BULKHEAD MOUNT HOUSING, RE	100
09200162691 HARTING	HAN 16A MALE 8PAIR TYPE J THERMO	0
09140014651 HARTING	MODULE USB MALE 4POS SCREW	23
09140153001 HARTING	HAN 15E-M-C MULTIPLIERBLOCK	47
09310062711 HARTING	INSERT FEMALE 6POS+1GND SCREW	14
09700142811 HARTING	INSERT FEMALE 14POS SCREW	0
09330162711 HARTING	INSERT FEMALE 16POS+1GND SCREW	11
09340062616 HARTING	INSERT MALE 6+2POS+1GND PUSH IN	0
09140023023 HARTING	MODULE MALE 2POS CRIMP	13
09380363001 HARTING	HAN K 9/9/18 MALE CRIMP INSERT (	24
09330242789 HARTING	INSERT FEMALE 24POS+1GND SCREW	0
09120043116 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	0
09340102701 HARTING	INSERT FEMALE 10+2POS+1GND SCREW	1
09120033151 HARTING	HAN Q3/0 -F- CRIMP	0
11053253001 HARTING	MODULE MALE 25POS CRIMP	20
09365242702 HARTING	HAN 24E EX FEMALE CRIMP INSERT U	9
09200032634 HARTING	INSERT MALE 3POS+1GND PUSH IN	10
09200103001 HARTING	INSERT MALE 10POS+1GND CRIMP	18

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).