Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09160243011 HARTING	INSERT 24POS HAN DD-PCI-C(25-48)	0
09110012670 HARTING	MODULE MALE 1POS SCREW	0
09100123106 HARTING	CRIMP INSERT FEMALE 12PIN	0
09140052703 HARTING	HAN E 5PIN FEMALE SCREW MODULE,	0
09330242721 HARTING	INSERT FEMALE 24POS SCREW	0
09806150100 HARTING	HAN-MODULAR PROFINET ID MODULE M	5
09120032760 HARTING	HAN BRID-RJ45 PANEL FEED THROUGH	0
09120062798 HARTING	HANBRIDPANELFEEDTHROUGH CU F PCR	0
09140033002SP HARTING	HAN 40AMP C 3PIN MODULE MALE CRI	0
09100032601 HARTING	1A 3+PE MALE SCREW INSERT SLATCH	0
09330242636 HARTING	INSERT MALE 24POS CRIMP	0
09330102652 HARTING	INSERT MALE 10POS CRIMP	0
09140012672 HARTING	HAN 1MOD-M-C 200A PE 25QMM	0
09200102832 HARTING	INSERT FEMALE 10POS SCREW	0
09140044514 HARTING	HAN MULTI MODULE, FEMALE (D-SUB)	0
09140203011 HARTING	MODULE W/O CONTACTS MALE CRIMP	0
09140403101 HARTING	INSERT FEMALE 40POS MOD-BU-C	0
09360162602 HARTING	HAN 16EX-M-C	0
09140052603 HARTING	HAN E 5PIN MALE SCREW MODULE, GO	0
09330162720 HARTING	INSERT FEMALE 16POS PUSH IN	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).