Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09338242703 HARTING	HAN HIGH TEMP 24E SCREW FEMALE	0
09142083011 HARTING	HAN GIGABIT HMC INSERT MALE	8
11051053011 HARTING	MODULE MALE 5POS CRIMP	0
09150043001 HARTING	INSERT MALE 4POS CRIMP	0
20700011001 HARTING	HAN ID-MODUL	1
09332102602 HARTING	HAN 10E HMC-M-CRIMP	9
09338102704 HARTING	HAN HIGH TEMP 10E CRIMP FEMALE	0
09142083012 HARTING	HAN GIGABIT HMC INSERT MALE (SHI	37
09155083001 HARTING	HAN F+B 4/4-M	44
09120073001 HARTING	INSERT MALE 7POS CRIMP	165
09210404711 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	2
09140044512 HARTING	MODULE FEMALE 4POS CRIMP/SOLDER	10
09120022751 HARTING	INSERT FEMALE 2POS+1GND SCREW	0
09120123104 HARTING	INSERT HAN Q 12/0 FEMALE 1,5MM	12
09140023025 HARTING	MODULE MALE 2POS CRIMP	0
09200163011 HARTING	INSERT MALE 16POS+1GND CRIMP	7
09200102814 HARTING	HAN 10A FEMALE SCREW TERMINAL IN	2
09162423101 HARTING	HAN 42DD-HMC-F-C	18
09380122601 HARTING	INSERT MALE 4+8POS+1GND SCREW	1
09120083001 HARTING	INSERT MALE 8POS+1GND CRIMP	5

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).