Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09155083101 HARTING	HAN F+B 4/4-F	43
09200032734 HARTING	INSERT FEMALE 3POS+1GND PUSH IN	8
09338102703 HARTING	HAN HIGH TEMP 10E SCREW FEMALE	0
09140013074 HARTING	HAN PE-MODULE MALE CRIMP 35QMM	8
11056483001 HARTING	MODULE MALE 48POS CRIMP	0
09140032602 HARTING	MODULE MALE 3POS SCREW	0
09380062701 HARTING	INSERT FEMALE 4+2POS+1GND SCREW	56
09330162702 HARTING	INSERT FEMALE 16POS+1GND CRIMP	0
09330064729 HARTING	INSERT FEMALE 6P+1GND TERM BLOCK	0
09700202817 HARTING	INSERT FEMALE 20POS SCREW	40
09338162604 HARTING	HAN HIGH TEMP 16E CRIMP MALE	0
09120062766 HARTING	INSERT FEMALE 4+2POS+1GND SCREW	6
09360242601 HARTING	HAN 24EX-M-S	0
09140022750 HARTING	MODULE FEMALE 2POS SCREW	4
09140022753 HARTING	MODULE FEMALE 2POS SCREW	45
09330162701 HARTING	INSERT FEMALE 16POS+1GND SCREW	124
09330242712 HARTING	INSERT FEMALE 24POS+1GND CRIMP	2
09160723011 HARTING	INSERT MALE 72POS+1GND CRIMP	51
09120062795 HARTING	INSERT FMALE 4+2POS+1GND PUSH IN	0
09140253101 HARTING	MODULE FEMALE 25POS CRIMP	232

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).