Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
20751081103 HARTING	HAN MODUL ELISA IN 0...200 C M	0
09330162620 HARTING	INSERT MALE 16POS PUSH IN	0
09140012675 HARTING	MODULE M8 SCREW BOLT	0
09330062652 HARTING	INSERT MALE 6POS CRIMP	0
09360162702 HARTING	HAN 16EX-F-C	0
09120033014 HARTING	HAN-BRID RJ45C-M FOR 10G RJ45	0
09360242702 HARTING	HAN 24EX-F-C	0
09140273021 HARTING	HAN SHIELDED MODULE 27PIN MALE C	25
09140012772 HARTING	HAN 1MOD-F-C 200A PE 25QMM	0
09110012750 HARTING	MODULE FEMALE 1POS SCREW	0
09330009907 HARTING	INSERT 24POS HAN E TEPC CONN	0
09100043006 HARTING	CRIMP INSERT 4PIN CAT5 MALE	0
09330242620 HARTING	INSERT MALE 24POS PUSH IN	0
09330242605 HARTING	INSERT MALE 24POS SCREW	0
09100033006 HARTING	1A 3+PE MALE SHIELD CRIMP LLEVER	0
09330242728 HARTING	INSERT FEMALE 24POS PUSH IN	0
09380052622 HARTING	INSERT MALE 3POS SCREW	0
09210644602 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	0
09100083106 HARTING	CRIMP INSERT 8PIN FEMALE	0
09380122753 HARTING	INSERT FEMALE 6+6POS+1GND	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).