Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120062662 HARTING	HAN Q 4/2 MALE AXIAL SCREW/QUICK	0
09210252601 HARTING	INSERT MALE 25POS+1GND WIRE WRAP	5
09120022651 HARTING	INSERT MALE 2POS+1GND SCREW	7
09332162748 HARTING	HAN 16E FEMALE ES PRESS INSERT,	10
09200103101 HARTING	INSERT FEMALE 10POS+1GND CRIMP	9
09120113001 HARTING	INSERT W/RJ45 MALE 8P8C+10P CRMP	7
09150083113 HARTING	INSERT FEMALE 8POS CRIMP	1
09330064726 HARTING	INSERT FEMALE 6P+1GND TERM BLOCK	5
09142083017 HARTING	HAN MEGABIT HMC INSERT MALE (SHI	99
09140023051 HARTING	MODULE MALE 2POS CRIMP	128
09120053004 HARTING	HAN Q 5/0 MALE CRIMP INSERT (16A	25
09142083016 HARTING	HAN MEGABIT HMC EINSATZ STI	36
09140123102 HARTING	HAN DD 12PIN MODULE FEMALE CRIMP	0
09140363001 HARTING	HAN HIGH DENSITY 36PIN MODULE MA	86
09200044711 HARTING	MODULE FIBER OPTIC SC FEMALE 4P	1
09330244635 HARTING	INSERT MALE 24P+1GND TERM BLOCK	0
09330162728 HARTING	INSERT FEMALE 16POS PUSH IN	3
09120033051 HARTING	HAN Q3/0 -M- CRIMP	0
09120013091 HARTING	INSERT W/USB FEMALE 4POS CRIMP	31
09140022651 HARTING	MODULE MALE 2POS SCREW	42

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).