Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140022741 HARTING	MODULE FEMALE 2POS SCREW	484
09140052717 HARTING	HAN ES 5PIN MODULE FEMALE CAGE C	3
09330242601 HARTING	INSERT MALE 24POS+1GND SCREW	0
09332062702 HARTING	HAN 6E HMC-F-CRIMP	11
09140083132 HARTING	HAN GIGABIT INSERT F CAT. 7 (SHI	5
09338162603 HARTING	HAN HIGH TEMP 16E SCREW MALE	7
09200032733 HARTING	INSERT FEMALE 3POS+1GND PUSH IN	0
09330062716 HARTING	INSERT FEMALE 6POS+1GND PUSH IN	7
09140012734 HARTING	HAN PE-MODULE FEM. AXIAL 38QMM	19
09140014701 HARTING	MODULE USB FEMALE 4POS	55
09380873001 HARTING	HAN K 32/55 MALE CRIMP INSERT (1	4
09110012675 HARTING	MODULE MALE 1POS SCREW	2
09140083011 HARTING	MODULE MALE 8POS CRIMP	297
09120022701 HARTING	MODULE FEMALE 2POS CRIMP	0
09120062765 HARTING	HAN Q 4/2 FEMALE AXIAL SCREW INS	0
09365102602 HARTING	HAN 10E EX MALE CRIMP INSERT UL	10
09200162616 HARTING	HAN 32A - 16A MALE SCREW TERMINA	0
09160752001 HARTING	HAN 75DDD MALE CRIMP INSERT	18
09120012651 HARTING	HAN Q 1/0 MALE AXIAL SCREW INSER	0
09380082701 HARTING	INSERT FMALE 4+4POS+1GND PUSH IN	0

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).