Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09330242726 HARTING	INSERT FEMALE 24POS+1GND PUSH IN	1
09330242711 HARTING	INSERT FEMALE 24POS+1GND SCREW	7
09120042713 HARTING	INSERT FEMALE 4POS+2 FIBER CRIMP	27
09930010102 HARTING	HAN S SCREW MOUNT HOUSING, RED,	100
09360062702 HARTING	HAN 6EX-F-C	0
09330242648 HARTING	HAN 24 ES PRESS - M	1
09365162601 HARTING	HAN 16E EX MALE SCREW TERMINAL I	6
09140033101 HARTING	MODULE FEMALE 3POS CRIMP	80
09140052646 HARTING	MODULE MALE 5POS CRIMP/SCREW	9
09150043114 HARTING	INSERT FEMALE HAN-QUINTAX 85	10
09110012655 HARTING	MODULE MALE 1POS SCREW	10
09332242602 HARTING	HAN 24E HMC-M-CRIMP	16
09120062694 HARTING	INSERT MALE 4+2POS+1GND SCREW	10
09338062703 HARTING	HAN HIGH TEMP 6E SCREW FEMALE	0
09380122651 HARTING	INSERT MALE 6+6POS+1GND SCREW	7
09100123000 HARTING	1A 12PIN MALE CRIMP INSERT WITH	59
09140044713 HARTING	HAN SC FIBER MODULE FEMALE INSER	0
09380182601 HARTING	INSERT MALE 6+12POS+1GND SCREW	1
09140023121 HARTING	MODULE FEMALE 2POS CRIMP	4
09340062602 HARTING	INSERT MALE 6+2POS+1GND CRIMP	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).