Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120052734 HARTING	INSERT FEMALE 5POS PUSH IN LOCK	511
09332062648 HARTING	HAN 6E MALE ES PRESS INSERT, HIG	10
09140173001 HARTING	MODULE MALE 17POS CRIMP	42
09140033003 HARTING	HAN 40AMP C 3PIN MODULE MALE CRI	15
09330104739 HARTING	INSERT FMALE 10P+1GND TERM BLOCK	0
09210642701 HARTING	INSERT FEMALE 64P+1GND WIRE WRAP	4
11051052802 HARTING	HAN YELLOCK MULTIPLIER 2:3	38
09332162648 HARTING	HAN 16E MALE ES PRESS INSERT, HI	10
09140013072 HARTING	HAN PE-MODULE MALE CRIMP 16QMM	0
09140022642 HARTING	MODULE MALE 2POS SCREW	15
09330062701 HARTING	INSERT FEMALE 6POS+1GND SCREW	118
09330062601 HARTING	INSERT MALE 6POS+1GND SCREW	0
09140013002 HARTING	HAN 1MOD-M-C 200A FINGER PROTECT	25
09140013173 HARTING	HAN PE-MODULE FEM. CRIMP 25QMM	0
09330242701 HARTING	INSERT FEMALE 24POS+1GND SCREW	79
09360083101 HARTING	INSERT FEMALE 8POS CRIMP	27
09200163101 HARTING	INSERT FEMALE 16POS+1GND CRIMP	6
09330102716 HARTING	INSERT FEMALE 10POS+1GND PUSH IN	3
09212643101 HARTING	HAN 64D-HMC-F-C	10
09332242702 HARTING	HAN 24E HMC-F-CRIMP	16

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).