Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09100123006 HARTING	CRIMP INSERT 12PIN MALE	0
09140022705 HARTING	MODULE FEMALE HAN 40A SCREW	0
09320463009 HARTING	INSERT MALE 46POS CRIMP	0
09806150200 HARTING	HAN-MODULAR PROFINET ID MODULE F	5
09330062752 HARTING	INSERT FEMALE 6POS CRIMP	0
09120032764 HARTING	HAN BRID-RJ45 PANEL FEED THROUGH	0
09100043106 HARTING	CRIMP INSERT 4PIN FEMALE	0
09330164735 HARTING	INSERT FMALE 16P+1GND TERM BLOCK	0
20751042201 HARTING	MODUL OUT 4...20MA F	0
09100043001 HARTING	CRIMP INSERT 4PIN MALE	0
09140273121 HARTING	HAN SHIELDED MODULE 27PIN FEMALE	17
09210643043 HARTING	INSERT MALE 64POS CRIMP	0
09110012770 HARTING	MODULE FEMALE 1POS SCREW	0
09380122681 HARTING	INSERT MALE 6+6POS+1GND	0
09140203111 HARTING	MODULE FEMALE CRIMP	0
09330242681 HARTING	INSERT MALE 24POS SCREW	0
09128053004 HARTING	HAN Q 5/0 MALE CRIMP INSERT (16A	8
09100032701 HARTING	1A 3+PE FEM SCREW INSERT SLATCH	0
09380122781 HARTING	INSERT FEMALE 6+6POS+1GND	0
09100053001 HARTING	1A 5+PE MALE CRIMP INSERT SLATCH	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).