Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140083031 HARTING	HAN GIGABIT INSERT M, CAT. 7	3
09330064736 HARTING	INSERT FEMALE 6P+1GND TERM BLOCK	0
09210153101 HARTING	INSERT FEMALE 15POS+1GND CRIMP	0
09330162712 HARTING	INSERT FEMALE 16POS+1GND CRIMP	9
09140423101 HARTING	HAN DD QUAD MODULE FEMALE	42
09365242602 HARTING	HAN 24E EX MALE CRIMP INSERT UL	11
09120012774 HARTING	INSERT FIREWIRE MALE 6POS CRIMP	0
09140012761 HARTING	MODULE FEMALE HAN 200A AXIAL	0
09930010502 HARTING	HAN S HOOD, ANGLED, RED, 25-50MM	200
09365162701 HARTING	HAN 16E EX FEMALE SCREW TERMINAL	5
09140083017 HARTING	MODULE MALE 8POS (2X4) CRIMP	66
09110012671 HARTING	MODULE MALE 1POS SCREW	1
09340032702 HARTING	INSERT FEMALE 3+2POS+1GND CRIMP	4
09330242619 HARTING	INSERT MALE 24POS PUSH IN	4
09800150100 HARTING	HAN-MODULAR CAN ID MODULE MALE	0
09210644712 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	1
09365102701 HARTING	HAN 10E EX FEMALE SCREW TERMINAL	5
09210152701 HARTING	INSERT FEMALE 15P+1GND WIRE WRAP	0
09200162615 HARTING	HAN 32A - 16A MALE SCREW TERMINA	3
09120033031 HARTING	INSERT RJ45 MALE 8P8C IDC	9

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).