Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
19410142601 HARTING	HAN-ECO 14E-M-S	5
09330244739 HARTING	INSERT FMALE 24P+1GND TERM BLOCK	5
09200102612 HARTING	INSERT MALE 10POS+1GND SCREW	31
09140063021 HARTING	HAN SHIELDED POWER MODULE, MALE	50
09110013012 HARTING	HAN HC MODULAR 650 MALE CRIMP TE	0
09140023041 HARTING	MODULE MALE 2POS CRIMP	326
09120053101 HARTING	INSERT FEMALE 5POS CRIMP	36
09160403001 HARTING	HAN 40DD MALE CRIMP INSERT	25
09140063101 HARTING	MODULE FEMALE 6POS CRIMP	3527
09338102604 HARTING	HAN HIGH TEMP 10E CRIMP MALE	0
09338242704 HARTING	HAN HIGH TEMP 24E CRIMP FEMALE	0
09330102791 HARTING	INSERT FEMALE 10POS+1GND SCREW	2
09212403001 HARTING	HAN 40D-HMC-M-C	13
09140022701 HARTING	MODULE FEMALE 2POS SCREW	117
09200032633 HARTING	INSERT MALE 3POS+1GND PUSH IN	15
09140052741 HARTING	MODULE FEMALE 5POS CRIMP/SCREW	9
09140122634 HARTING	MODULE MALE 12POS PUSH IN LOCK	13
09200032711 HARTING	INSERT FEMALE 3POS+1GND SCREW	106
09120023051 HARTING	INSERT MALE 2POS+1GND CRIMP	53
09330064625 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	2

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).