Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09380082702 HARTING	INSERT FMALE 4+4POS+1GND PUSH IN	2
09140082734 HARTING	MODULE FEMALE 8POS PUSH IN LOCK	8
09330242716 HARTING	INSERT FEMALE 24POS+1GND PUSH IN	1
09210073031 HARTING	INSERT MALE 7POS+1GND CRIMP	28
09140023103 HARTING	HAN 31AMP C 2PIN MODULE FEMALE C	0
09120173001 HARTING	INSERT MALE 17POS CRIMP	49
09100083101 HARTING	CRIMP INSERT 8PIN FEMALE	0
09140123001XL HARTING	HAN DD 12PIN MODULE MALE CRIMP (	0
09210153102 HARTING	INSERT FEMALE 15POS CRIMP	0
09100033106 HARTING	1A 3+PE FEM SHIELD CRIMP LLEVER	0
09140203012 HARTING	MODULE W/O CONTACTS MALE CRIMP	0
09161083117 HARTING	INSERT W/O CONTACTS 108POS CRIMP	0
09210644612 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	0
09310062751 HARTING	INSERT FEMALE 6POS+1GND SCREW	0
09100022606 HARTING	1A 2+PE MALE SCREW INSERT LLEVER	0
09340060501 HARTING	INSERT FEMALE 24POS HAN ESS	0
20703024922 HARTING	HAN 3A METALL OUTLET CAT 5	0
09330064636 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
09330242682 HARTING	INSERT MALE 24POS CRIMP	0
09120123103 HARTING	INSERT FEMALE 12POS SCREW	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).