Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09142083117 HARTING	HAN MEGABIT HMC INSERT FEM. (SHI	123
09451001110 HARTING	INSERT RJ45 MALE IDC	0
09162423001 HARTING	HAN 42DD-HMC-M-C	7
09120062762 HARTING	HAN Q 4/2 FEMALE AXIAL SCREW/QUI	0
09140122732 HARTING	MODULE FEMALE 12POS PUSH IN LOCK	103
09380082602 HARTING	INSERT MALE 4+4POS+1GND PUSH IN	1
09100123005 HARTING	1A 12PIN MALE CRIMP INSERT FOR L	51
09330102701 HARTING	INSERT FEMALE 10POS+1GND SCREW	33
09140013101 HARTING	MODULE FEMALE 1POS CRIMP	31
09140022604 HARTING	MODULE MALE 2POS SCREW	0
09140073101 HARTING	MODULE FEMALE 3+4POS CRIMP	0
09200042734 HARTING	INSERT FEMALE 4POS+1GND PUSH IN	8
09700062813 HARTING	INSERT FEMALE 6POS SCREW	20
09330162691 HARTING	INSERT MALE 16POS SCREW	6
09200162812 HARTING	INSERT FEMALE 16POS+1GND SCREW	46
09120113111 HARTING	INSERT W/RJ45 FEMALE 8P8C+10P	2
09150043011 HARTING	INSERT MALE 4POS CRIMP	1
09140173101 HARTING	MODULE FEMALE 17POS CRIMP	372
11051052634 HARTING	HAN-YELLOCK QUICKLOCK MODULE FOR	31
09162723101 HARTING	HAN 72DD-HMC-F-C	3

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).