Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09120062698 HARTING	HANBRIDPANELFEEDTHROUGH CU MALE	0
09380082611 HARTING	INSERT MALE 4+4POS+1GND PUSH IN	0
09330162629 HARTING	INSERT MALE 16POS CRIMP	0
09140273122 HARTING	HAN SHIELDED MODULE 27PIN FEMALE	25
09330242754 HARTING	INSERT FEMALE 24POS CRIMP	0
09330162719 HARTING	INSERT FEMALE 16POS PUSH IN	0
09210404712 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	0
09140013033 HARTING	HAN GND MODULE MALE SHORT VERS	0
09210153002 HARTING	INSERT MALE 15POS+1GND CRIMP	0
09140022605 HARTING	MODULE MALE SCREW HAN 40A AXIAL	0
09320640001 HARTING	HAN 64EEE PANEL FEED THROUGH	0
09160243111 HARTING	INSERT FEMALE 24POS HAN DD-BU-C	0
09140403001 HARTING	INSERT MALE 40POS HAN MOD-PCI-C	0
09380182702 HARTING	INSERT FEMALE 6+12POS+1GND SCREW	0
09330064629 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
09330062656 HARTING	INSERT MALE 4+2POS+1GND PUSH IN	0
09200103103 HARTING	INSERT FEMALE 10POS CRIMP	0
09100032706 HARTING	1A 3+PE FEM SCREW INSERT LLEVER	0
09330164736 HARTING	INSERT FMALE 16P+1GND TERM BLOCK	0
09150043014 HARTING	INSERT MALE HAN-QUINTAX 85-10	10

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).