Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09310062651 HARTING	INSERT MALE 6POS+1GND SCREW	13
09140012763 HARTING	MODULE FEMALE 1POS SCREW	2
09320323101 HARTING	INSERT FEMALE 32POS+1GND CRIMP	0
09140083131 HARTING	HAN GIGABIT INSERT F, CAT. 7	5
09360242701 HARTING	HAN 24EX-F-S	0
09120012751 HARTING	HAN Q 1/0 FEMALE AXIAL SCREW INS	0
09320463011 HARTING	INSERT MALE 46POS+1GND CRIMP	11
09140013132 HARTING	MODULE FEMALE 1POS CRIMP/SCREW	60
09140083122 HARTING	HAN MEGABIT SINGLE ENTRY 2SHIELD	8
09330104635 HARTING	INSERT MALE 10P+1GND TERM BLOCK	0
09140082633 HARTING	MODULE MALE 8POS PUSH IN LOCK	27
09452001100 HARTING	INSERT RJ45 8P8C HAN3A CAT5 PFT	17
09140073001 HARTING	MODULE MALE 3+4POS CRIMP	78
09120032770 HARTING	INSERT RJ45 FEMALE 8P8C SCREW	69
09330162688 HARTING	HAN 32ES - 16ES PRESS MALE INSER	0
09162083001 HARTING	HAN 108DD-HMC-M-C	1
09320323111 HARTING	INSERT FEMALE 32POS+1GND CRIMP	4
09120032776 HARTING	INSERT RJ45 FEMALE 8P8C IDC	10
09332102748 HARTING	HAN 10E FEMALE ES PRESS INSERT,	17
11051052633 HARTING	MODULE MALE 5POS PUSH IN LOCK	34

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).